A soft magnetic alloy powder contains soft magnetic alloy particles. The soft magnetic alloy particles contain Fe and Si. The soft magnetic alloy particles each include crystal grains and crystal grain boundary between the crystal grains. At least one of the crystal grains has a Si segregation part.

A magnetic powder contains a magnetic metal particle comprising iron (Fe) and an insulating coating layer disposed on a surface of the magnetic metal particle and comprising tin (Sn), phosphorous (P) and oxygen (O), and a coil component contains such a magnetic powder.

Zinc is added to a metal magnetic alloy powder including iron and silicon. An element is formed using this magnetic material, and a coil is formed inside or on the surface of the element.

An magnetic component structure with thermal conductive filler is provided in the present invention, including an upper magnetic core, a lower magnetic core combining with the upper magnetic core to form a casing with a front opening and a rear opening, and a coil mounted in the casing, where two terminals of the coil extend outwardly from the front opening, and a thermal conductive filler filling between the casing and the coil in the casing.

A supersaturated solid solution soft magnetic material and a preparation method thereof are provided, belonging to the field of metal soft magnetic technologies. The supersaturated solid solution soft magnetic material is soft magnetic alloy with proportions of 72.0˜78.0 at % Fe, 12.0˜18.0 at % Si, 4.0˜12.0 at % Co and 1.0˜3.0 at % Ti. The preparation method uses molten glass purification or electromagnetic levitation melting to an alloy melt with a target supercooling degree, increases the solid solubility of the Ti element in α-Fe (Si, Co), and promotes the formation of supersaturated solid solution of Ti, thereby achieving the goal that the magnetocrystalline anisotropy constant and the magnetostriction coefficient tend to be zero. Ti element is uniformly distributed in the α-Fe (Si, Co) after supercooled solidification analyzed by X-ray energy spectrometer, a supersaturated solid solution alloy without Ti precipitation is obtained, and the soft magnetic alloy has low coercivity and high permeability.

The dust core comprises a plurality of soft magnetic iron-based particles, a coating layer disposed on each of the surfaces of the soft magnetic iron-based particles, an interstitial layer disposed between the coating layers, and a nanopowder disposed between the soft magnetic iron-based particles. The coating layer is a layer of a compound comprising Fe, Si, O, B and N; and the nanopowder is a powder of a compound comprising O, N and at least one element selected from the group consisting of Fe, Si, Zr, Co, Al, Mg, Mn and Ni.

A silicon oxide-coated soft magnetic powder, in which the ratio of a volume-based cumulative 50% particle diameter D50 (HE) according to a dry laser diffraction particle size distribution analysis to the same particle diameter D50 (MT) according to a wet laser diffraction particle size distribution analysis is 0.7 or more, and a coverage ratio R defined by R=Si×100/(Si+M) (Si and M are molar fractions of Si and elements constituting the soft magnetic powder) is 70% or more is obtained by subjecting a slurry containing a soft magnetic powder containing 20 mass % or more of iron and a hydrolysate of a silicon alkoxide to a dispersion treatment when the surface of the soft magnetic powder is coated with the hydrolysate in a mixed solvent of water and an organic substance. The powder has good insulation/dispersibility properties and a high filling factor during molding.

An insulating material-coated soft magnetic powder includes: a core particle that includes a base portion containing a soft magnetic material containing Fe as a main component and at least one of Si, Cr, and Al, and that includes an oxide film provided on a surface of the base portion and containing an oxide of at least one of Si, Cr, and Al; and an insulating film that is provided on a surface of the core particle and that contains a ceramic, in which a thickness of the insulating film is 5 nm or more and 300 nm or less, and the oxide contained in the oxide film and the ceramic contained in the insulating film are mutually diffused at an interface between the oxide film and the insulating film.

A magnetic base body according to one embodiment of the invention includes soft magnetic metal particles that have an insulating film on their surfaces. In a Raman spectrum obtained by observing light scattered when the magnetic base body is irradiated with an excitation laser with a wavelength of 488 nm, a peak intensity ratio. that is defined as a ratio of the peak intensity of a first peak existing at around a wave number of 712 cm.sup.−1 to the peak intensity of a peak existing at around a wave number of 1320 cm.sup.−1, is 1 to 70.

A coil component includes a body that is made of a composite material containing a resin material and metal powder, a coil conductor which is provided in the body and an end portion of which is exposed on an end face of the body, and a metal film that is provided on an outer surface of the body and that is electrically connected to the coil conductor on the end face in the outer surface. The outer surface of the body has a contact area that is in contact with the metal film. Multiple particles of the metal powder escape from the resin material and are in contact with each other in the contact area of the body.