Soft magnetic alloy core structure and electronic device including same

Abstract

A soft magnetic alloy core structure is provided. According to an embodiment of the present invention, the soft magnetic alloy core structure includes soft magnetic alloy powder, a binder, and an insulating material, wherein the soft magnetic alloy powder has a particle size distribution D50 of 14 to 40 μm. This configuration enables high magnetic permeability and low core loss while allowing implementation in complex shapes.

Description

Soft magnetic alloy core structure and electronic device including the same

[0001] The present invention relates to a soft magnetic alloy core structure, and more particularly, to a soft magnetic alloy core structure and an electronic device including the same.

[0002] Soft magnetic materials are widely used as core materials for various transformers, choke coils, various sensors, saturable reactors, magnetic switches, etc., and for power supply or conversion in distribution transformers, laser power sources, and accelerators, and as shielding materials against electromagnetic waves or magnetic fields in various electrical and electronic devices. In the electrical and electronic fields, the market demand for soft magnetic materials is for miniaturization and lightweight, high performance / efficiency, and low product cost. To satisfy such market demands, active research is being conducted on soft magnetic materials with high permeability and low core loss.

[0003] Meanwhile, oxide ferrite, which has a high permeability despite its low cost, has been widely used in the past. However, magnetic cores made of such oxide ferrite tend to have significantly increased core loss at high frequencies. In addition, to solve the above problem, a compacted magnetic core was developed by insulating and compressing soft magnetic powder, which exhibited relatively high permeability and low core loss, but there were many limitations in implementing a core structure with a complex shape.

[0004]

[0005] Accordingly, there is an urgent need to develop a core structure that has a high investment rate, low core loss, and can be implemented in complex shapes.

[0006] The present invention has been devised to solve the above-mentioned conventional problems, and its purpose is to provide a soft magnetic alloy core structure in which the particle size and composition of soft magnetic alloy powder are designed to have a high investment rate while minimizing core loss, and an electronic device including the same.

[0007] In addition, another object of the present invention is to provide a soft magnetic alloy core structure that can be implemented in a complex shape while having a high investment rate and low core loss, and an electronic device including the same.

[0008] In order to solve the above-described problem, the present invention provides a press-formed soft magnetic alloy core structure comprising a soft magnetic alloy powder, a binder, and an insulating material, wherein the soft magnetic alloy powder has a particle size distribution D50 of 14 to 40 ㎛.

[0009] According to one embodiment of the present invention, the soft magnetic alloy powder may have a ratio of particle size distribution D50 and particle size distribution D10 of 1:0.13 to 0.9.

[0010] In addition, the above-mentioned soft magnetic alloy powder may have a ratio of particle size distribution D50 and particle size distribution D90 of 1:1.1 to 6.1.

[0011] In addition, the above-mentioned soft magnetic alloy powder may have a particle size distribution D10 of 5.5 to 12.5 μm and a particle size distribution D90 of 46 to 84 μm.

[0012] In addition, the above-mentioned soft magnetic alloy powder may be an Fe-based soft magnetic alloy powder including at least one of an Fe-Ni-based soft magnetic alloy powder, an Fe-Si-based soft magnetic alloy powder, and an Fe-Si-Al-based soft magnetic alloy powder.

[0013] Additionally, the insulating material may include at least one of a metal oxide-based insulating material and a phosphate-based insulating material.

[0014] Additionally, the insulating material may include a metal oxide-based insulating material and a phosphate-based insulating material in a weight ratio of 1:0.04 to 1.45.

[0015] Additionally, the metal oxide-based insulating material may include at least one of Al2O3 and SiO2.

[0016] In addition, the metal oxide-based insulating material may include Al2O3 and SiO2 in a weight ratio of 1:0.12 to 0.85.

[0017] Additionally, the binder may include a silicon-based binder.

[0018] In addition, the binder may be included in an amount of 0.3 to 1.5 parts by weight and the insulating material may be included in an amount of 0.5 to 3.5 parts by weight per 100 parts by weight of the soft magnetic alloy powder.

[0019] Additionally, the investment ratio may be greater than 50, and the core loss may be less than or equal to 200 mW / cm3 at a frequency of 50 kHz and 0.1 Tesla, and less than or equal to 150 mW / cm3 at a frequency of 100 kHz and 0.05 Tesla.

[0020]

[0021] In addition, the present invention provides an electronic device including the above-described soft magnetic alloy core structure.

[0022]

[0023] Meanwhile, the terms "particle size distribution D10", "particle size distribution D50", and "particle size distribution D90" used in this specification respectively refer to particle sizes when the cumulative degrees are 10%, 50%, and 90%, respectively, in the volume cumulative particle size distribution. Specifically, in a graph (volume-based particle size distribution) in which the horizontal axis represents particle size and the vertical axis represents the volume cumulative frequency from the side with the smallest particle size, the particle sizes corresponding to the volume % cumulative values ​​from the smallest particle size of 10%, 50%, and 90%, respectively, of the total volume cumulative value (100%) of particles correspond to D10, D50, and D90, respectively. The above volume cumulative particle size distribution can be measured using a laser diffraction scattering particle size distribution device.

[0024] The soft magnetic alloy core structure of the present invention and the electronic device including the same have the effects of high investment rate and low core loss, while being capable of being implemented in a complex shape.

[0025] FIG. 1 is a schematic diagram of a soft magnetic alloy core structure according to one embodiment of the present invention.

[0026] Hereinafter, embodiments of the present invention will be described in detail so that those skilled in the art can easily implement the invention. The present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[0027]

[0028] The soft magnetic alloy core structure according to the present invention includes soft magnetic alloy powder, a binder, and an insulating material, and is implemented such that the particle size distribution D50 of the soft magnetic alloy powder is 14 to 40 ㎛.

[0029] As described above, the soft magnetic alloy powder included in the soft magnetic alloy core structure of the present invention may have a particle size distribution D50 of 14 to 40 ㎛, and preferably, a particle size distribution D50 of 14.1 to 39 ㎛. If the particle size distribution D50 of the soft magnetic alloy powder is less than 14 ㎛, the permeability may decrease, the powder manufacturing itself may be difficult, and the unit price may increase, and if the particle size distribution D50 of the soft magnetic alloy powder exceeds 40 ㎛, the core loss may increase, and the formability may decrease, so that the shape implementation ability may decrease.

[0030] In addition, the ratio of particle size distribution D50 and particle size distribution D10 of the above soft magnetic alloy powder may be 1:0.13 to 0.9, and preferably, the ratio may be 1:0.15 to 0.83. If the ratio of particle size distribution D50 and particle size distribution D10 of the above soft magnetic alloy powder is less than 1:0.13, the permeability may decrease, the core loss may increase, and the formability may decrease, thereby deteriorating the shape implementation, and if the ratio of particle size distribution D50 and particle size distribution D10 exceeds 1:0.85, the core loss may increase, the permeability may decrease, the powder manufacturing itself may be difficult, and the unit price may increase.

[0031] In addition, the ratio of particle size distribution D50 and particle size distribution D90 of the above soft magnetic alloy powder may be 1: 1.1 to 6.1, and preferably, the ratio may be 1: 1.2 to 5.9. If the ratio of particle size distribution D50 and particle size distribution D90 of the above soft magnetic alloy powder is less than 1: 1.1, core loss may increase and magnetic permeability may decrease, and if the ratio of particle size distribution D50 and particle size distribution D90 exceeds 1: 6.1, magnetic permeability may decrease, powder manufacturing itself may be difficult, formability may decrease, shape realization may decrease, and even if a complex shape is realized, the mechanical strength of the structure may decrease, the unit price may increase, and core loss may increase.

[0032] And, the soft magnetic alloy powder may have a particle size distribution D10 of 5.5 to 12.5㎛ and a particle size distribution D90 of 46 to 84㎛, and preferably, a particle size distribution D10 of 5.9 to 11.6㎛ and a particle size distribution D90 of 47.6 to 81.8㎛. If the particle size distribution D10 of the soft magnetic alloy powder is less than 5.5㎛, the magnetic permeability may decrease, and if the particle size distribution D10 exceeds 12.5㎛, the core loss may increase. In addition, if the particle size distribution D90 of the soft magnetic alloy powder is less than 46㎛, the magnetic permeability may decrease, and if the particle size distribution D90 exceeds 84㎛, the formability may decrease, so that the shape realization may decrease, and even if a complex shape is realized, the mechanical strength of the structure may decrease, and the core loss may increase.

[0033]

[0034] Hereinafter, each component of the soft magnetic alloy core structure of the present invention will be described.

[0035] The soft magnetic alloy core structure according to the present invention is press-molded, and satisfies the particle size distribution D50, particle size distributions D10 and D90, the ratio of particle size distributions D50 and D90, and the ratio of particle size distributions D50 and D10 of the soft magnetic alloy powder described above according to the present invention, and satisfies the composition described below, so that even though it is press-molded, it can be implemented in a complex shape as shown in FIG. 1 while exhibiting high permeability and low core loss.

[0036] First, the above-mentioned soft magnetic alloy powder will be described.

[0037] The above soft magnetic alloy powder may be any soft magnetic alloy powder commonly used in the art without limitation, but preferably, it may be an Fe-based soft magnetic alloy powder including at least one of an Fe-Ni-based soft magnetic alloy powder, an Fe-Si-based soft magnetic alloy powder, and an Fe-Si-Al-based soft magnetic alloy powder, and more preferably, an Fe-Ni-based soft magnetic alloy powder may be more advantageous in that it has a high permeability and a low core loss while being capable of being implemented in a complex shape.

[0038] At this time, if the soft magnetic alloy powder contains Fe without any one or more of Ni, Si, and their alloys, it is not easy to realize an amorphous initial alloy, and it may be difficult to manufacture a soft magnetic alloy with a uniform microstructure. However, if it contains any one or more of Ni, Si, and their alloys together with Fe, it may be more advantageous in terms of high permeability and low core loss, while also allowing for implementation in complex shapes.

[0039] Meanwhile, the soft magnetic alloy powder may further include inevitable impurities that can be included in typical soft magnetic alloys. The impurities may be elements known to be typically contained in soft magnetic alloys, such as C, N, S, and O. The content of the impurities may be allowed within a range that does not affect the achievement of the desired magnetic properties and the manufacturing process, and may be, for example, less than 1 wt%, and more preferably less than 0.5 wt%, in the alloy.

[0040]

[0041] Next, the above binder will be described.

[0042] The above binder is mixed with the above-described soft magnetic alloy powder and the insulating material described below to have insulating properties as well as a function of fixing the soft magnetic alloy powder and the insulating material. Any binder that can perform the function of fixing the soft magnetic alloy powder and the insulating material as well as an insulating property when mixed with the above-described soft magnetic alloy powder and the insulating material described below may be used without limitation, but preferably, it may include at least one of a water glass-based binder and a silicon-based binder, and more preferably, a silicon-based binder is included to be more advantageous in achieving the purpose of the present invention, as it can have the function of fixing the soft magnetic alloy powder and the insulating material as well as an insulating property when mixed with the above-described soft magnetic alloy powder and the insulating material described below.

[0043] In addition, the binder may be included in an amount of 0.3 to 1.5 parts by weight relative to 100 parts by weight of the soft magnetic alloy powder, and preferably, 0.1 to 1.2 parts by weight relative to 100 parts by weight of the soft magnetic alloy powder. If the binder is included in an amount of less than 0.3 parts by weight relative to 100 parts by weight of the soft magnetic alloy powder, core loss may increase, and even if a complex shape is implemented, the mechanical strength of the structure may decrease, and if it exceeds 1.5 parts by weight, the permeability may decrease.

[0044]

[0045] Next, the above insulating material will be described.

[0046] The above insulating material has the function of providing insulating performance to the soft magnetic alloy core structure, and any insulating material capable of providing insulating performance to the soft magnetic alloy core structure may be used without limitation, but preferably, at least one of a metal oxide-based insulating material and a phosphate-based insulating material may be included, and more preferably, including both a metal oxide-based insulating material and a phosphate-based insulating material may be more advantageous in achieving the purpose of the present invention along with excellent insulating performance.

[0047] In addition, the insulating material may include the metal oxide-based insulating material and the phosphate-based insulating material in a weight ratio of 1:0.04 to 1.45, and preferably, the metal oxide-based insulating material and the phosphate-based insulating material in a weight ratio of 1:0.05 to 1.43. By satisfying the weight ratio of the metal oxide-based insulating material and the phosphate-based insulating material included in the insulating material, the core loss is low, the permeability is high, and the implementation of a complex shape is possible, while the mechanical strength of the implemented structure can exhibit excellent effects.

[0048] In addition, the metal oxide-based insulating material may include at least one of Al2O3 (aluminum oxide) and SiO2 (silicon oxide) for the purpose of improving magnetic properties and controlling permeability through insulation, and preferably, including both Al2O3 (aluminum oxide) and SiO2 (silicon oxide) may be more advantageous in achieving the purpose of the present invention along with excellent insulation performance.

[0049] At this time, the metal oxide-based insulating material may contain Al2O3 (aluminum oxide) and SiO2 (silicon oxide) in a weight ratio of 1:0.12 to 0.85, and preferably, the insulating material may contain Al2O3 (aluminum oxide) and SiO2 (silicon oxide) in a weight ratio of 1:0.133 to 0.8. If the metal oxide-based insulating material contains Al2O3 (aluminum oxide) and SiO2 (silicon oxide) in a weight ratio less than 1:0.12, core loss may be reduced, and if the metal oxide-based insulating material contains Al2O3 (aluminum oxide) and SiO2 (silicon oxide) in a weight ratio exceeding 1:0.85, permeability may be reduced, and even if a complex shape is implemented, the mechanical strength of the structure may be reduced.

[0050] In addition, the insulating material may be included in an amount of 0.5 to 3.5 parts by weight relative to 100 parts by weight of the soft magnetic alloy powder, and preferably, may be included in an amount of 0.7 to 3 parts by weight relative to 100 parts by weight of the soft magnetic alloy powder. If the insulating material is included in an amount of less than 0.5 parts by weight relative to 100 parts by weight of the soft magnetic alloy powder, core loss may increase, and if the insulating material is included in an amount of more than 3.5 parts by weight relative to 100 parts by weight of the soft magnetic alloy powder, permeability may decrease, and even if a complex shape is implemented, the mechanical strength of the structure may decrease.

[0051]

[0052] The soft magnetic alloy core structure according to the present invention may have a permeability of 50 or more, preferably a permeability of 52 or more, and a core loss of 200 mW / cm3 or less at a frequency of 50 kHz and 0.1 Tesla, and may be 150 mW / cm3 or less at a frequency of 100 kHz and 0.05 Tesla, and preferably a core loss of 180 mW / cm3 or less at a frequency of 50 kHz and 0.1 Tesla, and may be 140 mW / cm3 or less at a frequency of 100 kHz and 0.05 Tesla.

[0053]

[0054] The soft magnetic alloy core structure according to the present invention can be manufactured according to the following manufacturing method, but is not limited thereto.

[0055] According to one embodiment of the present invention, the soft magnetic alloy core structure according to the present invention

[0056] It can be manufactured through a manufacturing method including a step of manufacturing a mixture by mixing a soft magnetic alloy powder, a binder, and an insulating material, a step of manufacturing a molded body by applying pressure to the mixture, and a step of manufacturing a soft magnetic alloy core structure by heat-treating the molded body.

[0057] Hereinafter, in the description of the method for manufacturing a soft magnetic alloy core structure, the description of the same parts as the description of the soft magnetic alloy core structure described above will be omitted.

[0058] First, the steps for preparing the above mixture will be described.

[0059] The step of preparing the above mixture may be performed using any mixing method commonly used in the art, and thus the present invention does not specifically limit this.

[0060] Meanwhile, in the step of manufacturing the mixture, a metal-based lubricant may be further added and mixed together with the soft magnetic alloy powder, binder, and insulating material.

[0061] As the above metal-based lubricant can be used without limitation as long as it is a metal-based lubricant that can be commonly used in the art, the present invention does not specifically limit it.

[0062] Next, the steps for manufacturing the above-mentioned molded body are described.

[0063] The step of manufacturing the above-mentioned molded body can be performed by applying pressure to the manufactured mixture as described above.

[0064] The above pressure can be applied through a mechanical press method, and the applied pressure can be 3 to 20 ton / ㎠, and preferably 5 to 15 ton / ㎠ can be more advantageous in achieving the purpose of the present invention.

[0065] Next, the steps for manufacturing the above-mentioned soft magnetic alloy core structure are described.

[0066] The step of manufacturing the above-described soft magnetic alloy core structure can be performed by heat-treating the above-described molded body as described above.

[0067] The above heat treatment may be more advantageous in achieving the purpose of the present invention when performed at a temperature of 700 to 800°C, preferably at a temperature of 710 to 790°C.

[0068] Meanwhile, in order to raise the temperature to the temperature for the heat treatment, the temperature can be raised through a temperature-maintaining temperature-raising process. The temperature-maintaining temperature-raising process can be performed with four or more temperature-maintaining sections, preferably five or more temperature-maintaining sections, and most preferably six temperature-maintaining sections.

[0069] When the above temperature maintenance and temperature increase process is performed with six temperature maintenance sections, each of the six temperature maintenance sections can be maintained at a predetermined temperature for 12 to 25 minutes, preferably 14 to 23 minutes, and the temperature maintenance section can gradually increase the temperature and maintain the temperature. In addition, the six temperature maintenance sections can be maintained at temperatures of 160 to 240°C, 260 to 340°C, 360 to 440°C, 460 to 540°C, 560 to 640°C, and 660 to 740°C, respectively, and preferably, it may be more advantageous to achieve the purpose of the present invention to maintain the temperatures at temperatures of 170 to 230°C, 270 to 330°C, 370 to 430°C, 470 to 530°C, 570 to 630°C, and 670 to 743°C, respectively.

[0070]

[0071] In addition, the present invention provides an electronic device including the above-described soft magnetic alloy core structure.

[0072] Since the above electronic device may correspond to a typical electronic device, the present invention does not specifically limit it.

[0073]

[0074] The soft magnetic alloy core structure of the present invention and the electronic device including the same have the effects of high investment rate and low core loss, while being capable of being implemented in a complex shape.

[0075] The present invention will be described in more detail through the following examples, but the following examples do not limit the scope of the present invention, and should be interpreted as helping to understand the present invention.

[0076] [Example]

[0077] <Example 1>

[0078] First, for 100 parts by weight of Fe-Ni soft magnetic alloy powder (weight ratio of Fe and Ni: 1:1.12) having a particle size distribution D10 of 5.94 μm, D50 of 15.87 μm, and D90 of 47.65 μm, 0.5 parts by weight of a silicon-based binder, 1 part by weight of a metal oxide-based insulating material containing Al2O3 and SiO2 in a weight ratio of 1:0.43 as an insulating material, and 0.3 parts by weight of a phosphate-based insulating material were mixed, and a metal lubricant was added to evenly mix the components to prepare a mixture. The mixture was molded using a mechanical press (150 ton, Samwon General Machinery) at a pressure of 10 ton / cm2, and the molded product was heat-treated at a temperature of 750℃ under a N2 atmosphere. At this time, the heat treatment was performed at 200°C for 18.5 minutes, 300°C for 18.5 minutes, 400°C for 18.5 minutes, 500°C for 18.5 minutes, 600°C for 18.5 minutes, and 700°C for 18.5 minutes, respectively, to reach the heat treatment temperature of 750°C, and then heat treatment was performed at 750°C for 60 minutes. Thereafter, cooling was performed while maintaining the temperature at 600°C for 18.5 minutes, 400°C for 18.5 minutes, 200°C for 18.5 minutes, and 100°C for 18.5 minutes, thereby manufacturing a soft magnetic alloy core structure having the shape shown in FIG. 1.

[0079]

[0080] <Examples 2 to 11 and Comparative Examples 1 to 2>

[0081] The same process as Example 1 was performed to manufacture the soft magnetic alloy core structure as shown in Tables 1 to 3 below, but by changing the particle size distributions D10, D50, and D90 of the soft magnetic alloy powder, the ratio of the particle size distributions D50 and D10, and the ratio of the particle size distributions D50 and D90.

[0082]

[0083] <Experimental Example>

[0084] For each of the soft magnetic alloy core structures manufactured according to the examples and comparative examples, the following physical properties were evaluated and are shown in Tables 1 to 3.

[0085] 1. Investment rate measurement

[0086] For each of the soft magnetic alloy core structures manufactured according to the examples and comparative examples, the inductance was evaluated under the conditions of 100 kHz and 1 V using an LCR Meter (E4980AL, KEYSIGHT) after winding 20 turns of copper wire coated with an insulating material on the winding section (10) of Fig. 1, and the permeability was measured.

[0087] 2. Core Loss Measurement

[0088] For each of the soft magnetic alloy core structures manufactured according to the examples and comparative examples, the left winding part of the winding part (10) of Fig. 1 was wound 20 times with an insulating material-coated copper wire, and then the right winding part was wound 10 times, and the core loss at 0.1 Tesla at 50 kHz and the core loss at 0.05 Tesla at 100 kHz were measured using BH Tracer (SY-8219, IWATSU).

[0089] 3. Evaluation of shape implementation

[0090] For each of the soft magnetic alloy core structures manufactured according to the Examples and Comparative Examples, it was confirmed whether the shape illustrated in Fig. 1 could be implemented, and the compressive strength in the lateral and vertical directions was measured using a strength tester. At this time, the measurement speed was 20 mm / min, and the lateral compressive strength was measured for the lowest part of the lateral T-shaped part of the upper structure in the soft magnetic alloy core structure illustrated in Fig. 1, and the vertical compressive strength was measured for the exact center of the upper surface of the upper structure in the soft magnetic alloy core structure illustrated in Fig. 1. In addition, when the lateral compressive strength was 15 kgf or more and the vertical compressive strength was 10 kgf or more, the strength was judged to be excellent, and if either of the two directions did not satisfy the value, the strength was evaluated to be reduced.

[0091] * For specimens that cannot be implemented with complex shapes, the investment rate and core loss are measured by winding the copper wire in the same area.

[0092] Classification Example 1 Example 2 Example 3 Example 4 Example 5 Soft magnetic alloy powder particle size distribution D10 (㎛) 5.94 5.91 1.56 4.72 13.51 particle size distribution D50 (㎛) 15.84 14.13 8.92 14.03 39.45 particle size distribution D90 (㎛) 47.65 47.68 1.84 6.22 83.77 ratio of D50 and D10 1:0.37 5 1:0.41 8 1:0.29 7 1:0.33 6 1:0.34 2 ratio of D50 and D90 1:3.0 1 1:3.3 8 1:2.10 1:3.29 1:2.12 magnetic permeability 5 45 2 59 44 6 7 core loss @ 50 kHz, 0.1T(mW / cm3)155150190153270 Core loss @100kHz, 0.05T(mW / cm3)767212175140 Shape realization evaluation possible possible possible possible possible possible, strength reduction

[0093] Classification Example 6 Example 7 Example 8 Example 9 Example 10 Soft magnetic alloy powder particle size distribution D10 (㎛) 5.64 12.38 5.12 12.90 15.42 particle size distribution D50 (㎛) 14.63 39.66 39.86 14.27 39.79 particle size distribution D90 (㎛) 43.47 86.69 96.60 39.80 43.57 ratio of D50 and D10 1:0.38 61:0.31 21:0.12 81:0.90 41:0.38 8 ratio of D50 and D90 1:2.97 1:2.19 1:2.4 21:2.79 1:1.09 magnetic permeability 44667 14647 core loss @50kHz(mW / ㎤)145240330270310Core loss @100kHz(mW / ㎤)70128210140190Shape implementation evaluation possible possible, strength reduction impossible possible possible possible

[0094] Classification Example 11 Comparative Example 1 Comparative Example 2 Soft magnetic alloy powder Particle size distribution D10 (㎛) 4.78 4.72 13.16 Particle size distribution D50 (㎛) 14.26 13.79 41.54 Particle size distribution D90 (㎛) 87.43 41.22 85.63 Ratio of D50 and D10 1:0.33 51:0.34 21:0.31 7 Ratio of D50 and D90 1:6.13 1:2.99 1:2.06 Permeability 734 47 1 Core loss @ 50 kHz (mW / ㎤) 410 146 350 Core loss @ 100 kHz (mW / ㎤) 240 72 215 Shape realization evaluation Complicated shape impossible Possible Complicated shape impossible

[0095] As can be seen from the above Tables 1 to 3, it can be confirmed that Examples 1 to 3, which satisfy all of the particle size distributions D10, D50, D90, the ratio of particle size distributions D50 and D10, and the ratio of particle size distributions D50 and D90 of the soft magnetic alloy powder according to the present invention, can simultaneously achieve the effects of significantly superior permeability, significantly lower core loss by frequency, and significantly superior shape realization, compared to Examples 4 to 11 and Comparative Examples 1 to 2, which do not satisfy even one of these.

[0096]

[0097] Although one embodiment of the present invention has been described above, the spirit of the present invention is not limited to the embodiment presented in this specification, and a person skilled in the art who understands the spirit of the present invention will be able to easily propose other embodiments by adding, changing, deleting, or adding components within the scope of the same spirit, but this will also be considered to fall within the spirit of the present invention.

[0098]

[0099] [Explanation of symbols]

[0100] 100: Soft magnetic alloy core structure

[0101] 10: Winding section

Claims

1. Contains a soft magnetic alloy powder, binder and insulating material, The above soft magnetic alloy powder has a particle size distribution D50 of 14 to 40㎛, and is a press-molded soft magnetic alloy core structure.

2. In paragraph 1, The above soft magnetic alloy powder is a soft magnetic alloy core structure having a particle size distribution D50 and particle size distribution D10 ratio of 1:0.13 to 0.

9.

3. In paragraph 1, The above soft magnetic alloy powder is a soft magnetic alloy core structure having a particle size distribution D50 and particle size distribution D90 ratio of 1:1.1 to 6.

1.

4. In paragraph 1, The above soft magnetic alloy powder is a soft magnetic alloy core structure having a particle size distribution D10 of 5.5 to 12.5 ㎛ and a particle size distribution D90 of 46 to 84 ㎛.

5. In paragraph 1, The above soft magnetic alloy powder is a soft magnetic alloy core structure which is an Fe-based soft magnetic alloy powder including at least one of an Fe-Ni-based soft magnetic alloy powder, an Fe-Si-based soft magnetic alloy powder, and an Fe-Si-Al-based soft magnetic alloy powder.

6. In paragraph 1, The above insulating material is a soft magnetic alloy core structure including at least one of a metal oxide-based insulating material and a phosphate-based insulating material.

7. In paragraph 1, The above insulating material is a soft magnetic alloy core structure containing a metal oxide-based insulating material and a phosphate-based insulating material in a weight ratio of 1:0.04 to 1.

45.

8. In paragraph 6, The above metal oxide-based insulating material is a soft magnetic alloy core structure containing at least one of Al2O3 and SiO2.

9. In paragraph 8, The above metal oxide-based insulating material is a soft magnetic alloy core structure containing Al2O3 and SiO2 in a weight ratio of 1:0.12 to 0.

85.

10. In paragraph 1, The above binder is a soft magnetic alloy core structure including a silicon-based binder.

11. In paragraph 1, A soft magnetic alloy core structure comprising 0.3 to 1.5 parts by weight of the binder and 0.5 to 3.5 parts by weight of the insulating material per 100 parts by weight of the soft magnetic alloy powder.

12. In paragraph 1, A soft magnetic alloy core structure having an investment ratio of 50 or more and a core loss of 200 mW / cm3 or less at a frequency of 50 kHz and 0.1 Tesla and of 150 mW / cm3 or less at a frequency of 100 kHz and 0.05 Tesla.

13. An electronic device comprising a soft magnetic alloy core structure according to any one of claims 1 to 12.

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