A pressed powder material according to embodiments is a pressed powder material including first magnetic metal particles having a first magnetic metal phase containing Fe and Co; and second magnetic metal particles having a second magnetic metal phase containing Fe, in which when the amounts of Co with respect to the total amounts of Fe and Co of the first and second magnetic metal particles are designated as Co1 and Co2, respectively, the ratio of Co2 to Co1 (Co2/Co1) is from 0 to 0.5, the average value of the ratio of the major axis to the minor axis is 2 or greater for the first magnetic metal particles and 1 or greater for the second magnetic metal particles, the second magnetic metal particles are present between the particles of the first magnetic metal particles, and the average value of the major axis of the second magnetic metal particles is equal to or longer than the average value of the major axis of the first magnetic metal particles.

In an IPM motor, since a first portion which is a pressed powder compact made of soft magnetic powder and has a lower magnetic permeability and a lower saturation magnetic flux density than those of a main body portion made of a laminated steel sheet is replaced and disposed in the vicinity of an inner arc side portion of a right end portion of a permanent magnet, local demagnetization is prevented.

In an IPM motor, since a first portion which is a pressed powder compact made of soft magnetic powder and has a lower magnetic permeability and a lower saturation magnetic flux density than those of a main body portion made of a laminated steel sheet is replaced and disposed in the vicinity of an inner arc side portion of a right end portion of a permanent magnet, local demagnetization is prevented.

A method to form a plurality of inductors in a single process by stacking multiple magnetic sheets, wherein each sheet is made to form a particular part in quantities, which can be a base part, a pillar part, a hollow part, or a cover part, for forming a magnetic body of an inductor.

A magnetic core comprises an anisotropic, composite material, which itself includes a matrix material (e.g., a dielectric, non-magnetic material, preferably a paramagnetic material), and magnetically aligned, ferromagnetic particles. The latter may for instance include micrometer- and/or nanometer-length scale particles. Such particles form chains of particles within the matrix material, wherein the chains form percolation paths of magnetic conduction. The paths extend along a first direction, whereby the chains extend, each, substantially along this first direction, while being distinct and distant from each other along a second direction that is perpendicular to the first direction and, possibly, to a third direction that is perpendicular to both the first direction and the second direction. Necking bridges are preferably formed between the particles. Related devices (e.g., inductor, amplifiers, transformers, etc.) and fabrication methods are also disclosed.

A magnetic core comprises an anisotropic, composite material, which itself includes a matrix material (e.g., a dielectric, non-magnetic material, preferably a paramagnetic material), and magnetically aligned, ferromagnetic particles. The latter may for instance include micrometer- and/or nanometer-length scale particles. Such particles form chains of particles within the matrix material, wherein the chains form percolation paths of magnetic conduction. The paths extend along a first direction, whereby the chains extend, each, substantially along this first direction, while being distinct and distant from each other along a second direction that is perpendicular to the first direction and, possibly, to a third direction that is perpendicular to both the first direction and the second direction. Necking bridges are preferably formed between the particles. Related devices (e.g., inductor, amplifiers, transformers, etc.) and fabrication methods are also disclosed.

Provided is a soft magnetic powder that can produce a dust core having excellent magnetic properties. The soft magnetic powder has a chemical composition, excluding inevitable impurities, represented by a composition formula of Fe.sub.aSi.sub.bB.sub.cP.sub.dCu.sub.eM.sub.f, where the M is at least one element selected from the group consisting of Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, Mn, C, Al, S, O, and N, 79 at %≤a≤84.5 at %, 0 at %≤b<6 at %, 0 at %<c≤10 at %, 4 at %<d≤11 at %, 0.2 at %≤e≤0.53 at %, 0 at %≤f≤4 at %, a+b+c+d+e+f=100 at %, a particle size is 1 mm or less, and a median of circularity of particles constituting the soft magnetic powder is 0.4 or more and 1.0 or less.

Provided is a soft magnetic powder that can produce a dust core having excellent magnetic properties. The soft magnetic powder has a chemical composition, excluding inevitable impurities, represented by a composition formula of Fe.sub.aSi.sub.bB.sub.cP.sub.dCu.sub.eM.sub.f, where the M is at least one element selected from the group consisting of Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, Mn, C, Al, S, O, and N, 79 at %≤a≤84.5 at %, 0 at %≤b<6 at %, 0 at %<c≤10 at %, 4 at %<d≤11 at %, 0.2 at %≤e≤0.53 at %, 0 at %≤f≤4 at %, a+b+c+d+e+f=100 at %, a particle size is 1 mm or less, and a median of circularity of particles constituting the soft magnetic powder is 0.4 or more and 1.0 or less.

A method for manufacturing a powder magnetic core, including a step of compacting a raw material powder to form a compact, a step of performing a first heat treatment on the compact to obtain a first heat-treated body, and a step of performing a second heat treatment on the first heat-treated body to obtain a second heat-treated body, wherein the raw material powder contains a soft magnetic powder and a lubricant that has a melting point Tm, the first heat treatment is performed in a temperature range from Tm to Tm+50° C. inclusive for a time longer than 10 minutes, and the second heat treatment is performed in a temperature range from 400° C. to 900° C. inclusive for a time of 3 minutes to 90 minutes inclusive, the temperature range of the second heat treatment being higher than the temperature range of the first heat treatment.

A method for manufacturing a powder magnetic core, including a step of compacting a raw material powder to form a compact, a step of performing a first heat treatment on the compact to obtain a first heat-treated body, and a step of performing a second heat treatment on the first heat-treated body to obtain a second heat-treated body, wherein the raw material powder contains a soft magnetic powder and a lubricant that has a melting point Tm, the first heat treatment is performed in a temperature range from Tm to Tm+50° C. inclusive for a time longer than 10 minutes, and the second heat treatment is performed in a temperature range from 400° C. to 900° C. inclusive for a time of 3 minutes to 90 minutes inclusive, the temperature range of the second heat treatment being higher than the temperature range of the first heat treatment.