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New composition and method

Inactive Publication Date: 2014-02-20
HOGANAS AB
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention offers a new way to produce pesticide cores for power electronics that have low core losses and high saturation flux density. Compared to previous methods, the invention does not require an organic binding agent in the powder composition, which allows for higher heat treatment temperatures without the risk of binding agent decomposition. The absence of organic material in the final core also makes it suitable for use in high-temperature environments. The invention provides an iron powder mixture and process methods that simplify the manufacturing process for these cores.

Problems solved by technology

When a magnetic material is exposed to a varying field, energy losses occur due to both hysteresis losses and eddy current losses.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0076]Two types of iron powder have been used as core particles; a pure water atomized iron powder having a content of iron above 99.5% by weight and a pure sponge iron having a content of iron above 99.5% by weight. The mean particle size of both types of powder was about 45 μm. The core particles have been mixed with grinded Sendust (typically 85% Fe, 9.5% Si and 5.5% Al) and the powder mix was then treated with a phosphorous containing solution according to WO2008 / 069749. Briefly, the coating solution was prepared by dissolving 30 ml of 85% weight of phosphoric acid in 1 000 ml of acetone, and 40 ml-60 ml of acetone solution was used per 1000 gram of powder. After mixing the phosphoric acid solution with the metal powder, the mixture is allowed to dry.

[0077]The obtained dry phosphorous coated iron-sendust mix powder was further blended with kaolin and sodium silicate according to the following table 1. After drying at 120° C. the powder was mixed with 0.6% Kenolube® and compacted...

example 2

[0083]To illustrate the possibility to dope pure phosphorous and kaolin-sodium silicate coated atomised iron powder with Sendust with only the first phosphorous coating layer and considerably enhance the magnetic properties of the compacted component the following samples were prepared. Table 2 also shows results from testing of the components.

TABLE 2Component propertiesAdditives on SendustCore loss atWt-%0.05 TPhosporousWt-%SodiumResistivityCoercivity 20 kHzSamplecoatingKaolinsilicate[μΩ· m][A / m][W / kg]50% Atomized iron phosphorous and kaolin − sodium silicate coated + 50% Sendust I-LI CompNo——25311699.5J CompNo2%0.4%45871409.0K InvYes——503541378.7L InvYes2%0.4%773941388.2

[0084]As can be seen from table 2, it is beneficial to have a first phosphorous coating layer on the sendust particles.

example 3

[0085]It is possible to control the magnetic properties of the compacted and heat treated component by varying the content of sendust in the atomized iron powder. The following samples have all been treated in the same way—a first layer of phosphorous coating and a second layer coating consisting of 2% kaolin clay and 0.4% sodium silicate, compacted to 800 MPa and heat treated in 700° C. for 0.5 h in a nitrogen atmosphere. The difference between the samples is that the sendust content in the atomized iron powder has been varied. Table 3 also shows results from testing of the components.

TABLE 3Component propertiesWt-%Resistivity μmaxCoercivityCore loss at 0.05 T Bs SampleSendust[μΩ· m][−][A / m]20 kHz [W / kg][T]Atomized iron + Sendust − different compositions, phosphorous coated and a second coating layer with 2% kaolin and 0.4% sodium silicate M-UM—200009722213.51.98CompN Inv2.5% 245889121613.01.95O Inv 5%527948721012.51.90P Inv10%514388520211.11.85Q Inv20%1135137917910.61.63R Inv30%10...

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Abstract

The present invention concerns a composite iron-based powder mix suitable for soft magnetic applications such as inductor cores. The present invention also concerns a method for producing a soft magnetic component and the component produced by the method.

Description

FIELD OF THE INVENTION[0001]The present invention concerns a soft magnetic composite powder material for the preparation of soft magnetic components as well as the soft magnetic components which are obtained by using this soft magnetic composite powder. Specifically the invention concerns such powders for the preparation of soft magnetic components materials working at high frequencies, the components suitable as inductors or reactors for power electronics.BACKGROUND OF THE INVENTION[0002]Soft magnetic materials are used for various applications, such as core materials in inductors, stators and rotors for electrical machines, actuators, sensors and transformer cores. Traditionally, soft magnetic cores, such as rotors and stators in electric machines, are made of stacked steel laminates. Soft magnetic composites may be based on soft magnetic particles, usually iron-based, with an electrically insulating coating on each particle. By compacting the insulated particles optionally togeth...

Claims

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Application Information

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IPC IPC(8): C22C38/02C22C38/06B22F3/16B22F1/102B22F1/16
CPCC22C38/02C22C38/06B22F3/16C22C33/0207H01F1/24H01F41/0246B22F9/082Y10T428/249921B22F1/16B22F1/102H01F41/02
Inventor YE, ZHOUSTAFFANSSON, HANNA
Owner HOGANAS AB
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