High-frequency power inductance material

Abstract

The invention relates to the field of inductance materials, and particularly discloses a high-frequency power inductance material. The high-frequency power inductance material comprises a magnet and a winding, the windings are distributed in the magnet in a staggered mode, and the two ends of the windings extend outwards to form electrodes. The magnet is composed of a Fe-based nanocrystalline material, and the Fe-based nanocrystalline material comprises the following components in percentage by weight: 59.0-78.5 wt% of Fe; si: 10 wt%-15 wt%; 7 wt% to 15 wt% of Co; mn: 1 wt%-3.5 wt%; b: 3 wt%-6 wt%; and 0.5 wt%-1.5 wt% of Cu. The high-frequency power inductance material solves the problem that an existing inductance material is large in material loss under high frequency.

Description

Technical Field

[0001] The present application relates to the field of inductor materials, and more specifically, to a high-frequency power inductor material. Background Art

[0002] With the rapid development of third-generation semiconductor materials, the losses of power switching transistors operating at high frequencies have been significantly reduced. To achieve device miniaturization, the operating frequency of power management circuits is experiencing a significant increase, from the traditional 1-10MHz range to high frequencies above 10MHz. At the same time, the current in the circuits is also increasing, placing higher demands on the performance of related electromagnetic components. Currently, high-power inductors generally utilize alloy-based magnetic materials. However, this type of material has a significant drawback: low resistivity. Under high-frequency operating conditions, low resistivity generates significant eddy currents, making eddy current losses a significant factor affecting inductor performance. Furthermore, the high interlayer capacitance between copper wires at high frequencies further exacerbates high-frequency losses. These issues reduce inductor efficiency at high frequencies, making it difficult to meet the efficient and stable operation requirements of modern power management circuits. The aforementioned high material loss problem at high frequencies adversely impacts the performance and application of inductor products. As the frequency of power management circuits continues to increase, failure to effectively address this issue will hinder the miniaturization and efficiency of the entire power system. Summary of the Invention

[0003] In order to solve the problem of large material loss of existing inductor materials at high frequencies, the present application provides a high-frequency power inductor material.

[0004] The high-frequency power inductor material provided in this application adopts the following technical solution: A high-frequency power inductor material, comprising a magnet and a winding; The windings are staggered and distributed inside the magnet, and electrodes are formed at both ends of the windings; The magnet is composed of Fe-based nanocrystalline material, and its components are as follows by weight percentage: Fe: 59.0wt%-78.5wt%; Si: 10wt%-15wt%; Co: 7wt%-15wt%; Mn: 1wt%-3.5wt%; B: 3wt%-6wt%; Cu: 0.5wt%-1.5wt%.

[0005] By adopting the above technical solution and using Fe-based nanocrystalline materials with a specific composition, the overall performance of the magnet at high frequencies has been significantly improved. Fe, as the main element, provides high saturation magnetic induction, while Si and Co work synergistically to optimize magnetic permeability and increase resistivity, thereby suppressing eddy current losses. The addition of Mn refines the grain structure and enhances material stability; Boron, as a glass-forming element, promotes nanocrystallization, while Cu further reduces hysteresis losses by regulating the grain boundary structure.

[0006] Optionally, the interlayer spacing of the winding is 1 to 2.5 times the winding wire diameter, and the spacing between the outermost layer of the winding and the magnet is 0.5-2 times the wire diameter; a magnetic isolation material layer is provided between the electrode portion of the winding extending out of the magnet and the magnet, and its thickness is 20-80 μm.

[0007] By adopting the above technical solutions, the staggered distribution of windings is combined with optimized interlayer spacing, structurally reducing the impact of high-frequency parasitic capacitance. The interlayer spacing is expanded to 1 to 2.5 times the wire diameter, weakening the electric field coupling between adjacent windings and effectively reducing interlayer capacitance. The outermost layer maintains a spacing of 0.5 to 2 times the wire diameter from the magnet to avoid additional losses caused by edge magnetic field distortion. The magnetic isolation material layer (20-80μm) at the electrode site blocks the leakage magnetic path between the magnet and the electrode through physical isolation, reducing stray magnetic field interference at high frequencies.

[0008] Optionally, the magnetic isolation material is a FeSiAl flake alloy, the composition of which is as follows by weight percentage: Fe: 87-88wt% Si: 6.5-7.5wt% Al: 3.5-6.5wt%.

[0009] By employing this technical solution, FeSiAl flake alloys are used as magnetic shielding materials, with their composition designed to balance high resistivity with magnetic shielding performance. The Fe-Si-Al ternary system has a near-zero magnetostriction coefficient, which reduces losses caused by magnetic domain wall vibrations. The addition of Si and Al increases the alloy's resistivity to over 100 μΩ·cm, an order of magnitude higher than conventional alloys. The flake structure further limits the eddy current path, significantly reducing eddy current losses at high frequencies compared to solid materials.

[0010] Optionally, the flaky alloy particles have a thickness of 1-3 μm and a diameter of 30-100 μm.

[0011] By adopting this technical solution, the particle size of the flake alloy (1-3μm thickness, 30-100μm diameter) optimizes the microstructure of the magnetic isolation layer. The smaller thickness reduces the length of the eddy current loop perpendicular to the magnetic field, while the moderate diameter ensures a continuous magnetic shielding layer between the particles. This size matching ensures stable magnetic permeability of the magnetic isolation layer at high frequencies. At the same time, the Al2O3 insulating layer formed by the confined solid-state reaction further suppresses leakage between the particles.

[0012] Optionally, the powder particle size of the Fe-based nanocrystals is 1-6 μm, and the grain size is 10-30 nm.

[0013] By adopting the above technical solution, the particle size (1-6μm) and grain size (10-30nm) of Fe-based nanocrystalline powder are designed to maximize the material's high-frequency response capability. The ultrafine grain structure can reduce the resistance to magnetic domain wall movement and reduce hysteresis loss; the smaller powder particle size ensures that the magnetic powder is evenly distributed during the pressing process, avoiding eddy current concentration caused by local density differences. This dual-scale structure enables the material to maintain high magnetic permeability in the frequency band above 10MHz, while also having a high saturation magnetic induction intensity, meeting the needs of high-power scenarios.

[0014] Optionally, the surface of the nanocrystalline powder is coated with a 5-10 nm insulating layer of aluminum oxide or silicon oxide.

[0015] By employing this technical solution, the 5-10nm insulating coating on the surface of the nanocrystalline powder effectively inhibits the conductive path between particles through physical isolation. The high resistivity of the aluminum oxide or silicon oxide layer blocks the lateral conduction of eddy currents, significantly reducing eddy current losses. Furthermore, the lattice matching of the coating and the magnetic powder strengthens the interfacial bonding, preventing the coating from shedding under high-frequency vibration.

[0016] Optionally, the magnet contains 0.5 wt% to 1.5 wt% of a resin mixture, and the resin mixture is selected from one or more of epoxy resin, silicone resin, and silicone resin.

[0017] By adopting this technical solution, the 0.5-1.5wt% resin mixture added to the magnet achieves dual effects in reducing high-frequency losses. The organic resin, such as epoxy, acts as a binder, forming a continuous insulating layer between the magnetic powder particles, preventing direct electrical contact between them. Simultaneously, the high resistivity of the resin further suppresses the lateral diffusion of eddy currents.

[0018] Optionally, the resin mixture is dispersed with nanofillers accounting for 10 wt% to 15 wt% of the resin mixture, and the nanofillers are one or more of AlN, BN, and Si3N4, and have a particle size of 18-40 nm.

[0019] By employing this technical solution, the nanofillers (AlN, BN, and Si3N4) dispersed in the resin optimize the material's overall performance through a synergistic effect. The high thermal conductivity of AlN and BN quickly dissipates heat within the magnet, reducing temperature rise. Si3N4, with its high dielectric strength, enhances insulation and reduces the risk of partial discharge. The nanofillers' particle size ensures uniform dispersion in the resin, forming a continuous thermally conductive and insulating network, further minimizing interparticle eddy current losses.

[0020] In summary, this application has the following beneficial effects: 1. Since this application adopts Fe-based nanocrystalline materials with specific components, combined with 1-6μm powder particle size, 10-30nm grain size and surface insulation coating design, and cooperates with the inter-particle insulation layer composed of resin mixture and nano-filler, the eddy current path is suppressed and the resistance to magnetic domain wall movement is reduced from the intrinsic characteristics of the material, thereby achieving a synergistic reduction of eddy current loss and hysteresis loss at high frequency.

[0021] 2. In this application, it is preferred to adopt a staggered winding distribution and control the interlayer spacing, optimize the distance between the winding and the magnet boundary, and combine it with a FeSiAl sheet alloy magnetic isolation layer to weaken the parasitic capacitance coupling between the windings, block the leakage magnetic path between the electrode and the magnet, and reduce the electromagnetic energy loss and stray magnetic field interference at high frequency.

[0022] 3. This application achieves a coordinated optimization of material composition, microstructure and device structure, so that the inductor material has high saturation magnetic induction intensity, low loss and stable magnetic permeability in the high frequency band above 10MHz. At the same time, the heat dissipation capacity is improved through the thermal conductive insulation composite system to meet the requirements of efficient and stable operation in high-frequency and high-current scenarios for increased power density and device miniaturization. DETAILED DESCRIPTION

[0023] The present application is further described in detail below with reference to the examples. It is particularly noted that if no specific conditions are specified in the following examples, the reactions are carried out according to conventional conditions or the conditions recommended by the manufacturer. Unless otherwise specified, the raw materials used in the following examples can be obtained from common commercial sources. Example

[0024] Example 1 A method for preparing high-frequency power inductor material: (1) Magnet preparation Fe70wt%, Si12wt%, Co10wt%, Mn2wt%, B5wt% and Cu1wt% were weighed according to weight percentage, and amorphous strip was prepared by melt quenching method. Nanocrystalline powder was obtained by annealing at 550℃ for 30min. The powder particle size was controlled to be 10μm and the grain size was 50nm. The powder was mixed with 0.8 wt % epoxy resin, pressed into a magnet blank with a size of Φ10 mm×5 mm under a pressure of 800 MPa, and cured at 120° C. for 2 h. (2) Winding preparation Φ0.3mm enameled copper wire is wound in a staggered spiral pattern, with the windings evenly distributed inside the magnet, and electrodes extending 5mm at both ends. The spacing between winding layers is 1 times the winding wire diameter, and the spacing between the outermost layer of the winding and the magnet is 0.5 times the wire diameter.

[0025] Example 2 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that 59wt% Fe, 15wt% Si, 15wt% Co, 3.5wt% Mn, 6wt% B, and 1.5wt% Cu are weighed in weight percentage, an amorphous strip is prepared by melt quenching, and nanocrystalline powder is obtained by annealing at 550°C for 30 minutes.

[0026] Example 3 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that 78.5wt% Fe, 10wt% Si, 7wt% Co, 1wt% Mn, 3wt% B, and 0.5wt% Cu are weighed in weight percentage, an amorphous strip is prepared by melt quenching, and nanocrystalline powder is obtained by annealing at 550°C for 30 minutes.

[0027] Example 4 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the interlayer spacing of the winding is 1.5 times the winding wire diameter.

[0028] Example 5 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the interlayer spacing of the winding is 2.5 times the winding wire diameter.

[0029] Example 6 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the distance between the outermost layer of the winding and the magnet is 1.2 times the wire diameter.

[0030] Example 7 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the distance between the outermost layer of the winding and the magnet is twice the wire diameter.

[0031] Example 8 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that a magnetic isolation material layer is provided between the electrode portion where the winding extends out of the magnet and the magnet. The thickness of the magnetic isolation material is 50±5 μm. The magnetic isolation material is a FeSiAl flake alloy with the following composition by weight percentage: Fe: 87.5wt% Si: 7wt% Al: 5.5wt%; The thickness of the flaky alloy particles is 1-3 μm and the diameter is 60±5 μm.

[0032] Example 9 A method for preparing a high-frequency power inductor material: The difference from Example 8 is that the thickness of the magnetic isolation material layer is 25±5 μm.

[0033] Example 10 A method for preparing a high-frequency power inductor material: The difference from Example 8 is that the thickness of the magnetic isolation material layer is 75±5 μm.

[0034] Example 11 A method for preparing a high-frequency power inductor material: The difference from Example 8 is that the thickness of the flaky alloy particles is 1-3 μm and the diameter is 35±5 μm.

[0035] Example 12 A method for preparing a high-frequency power inductor material: The difference from Example 8 is that the thickness of the flaky alloy particles is 1-3 μm and the diameter is 95±5 μm.

[0036] Example 13 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the powder particle size of the Fe-based nanocrystal is 1-6 μm, and the grain size is 10-30 nm.

[0037] Example 14 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the surface of the nanocrystalline powder is coated with a 5-10 nm aluminum oxide insulating layer.

[0038] Example 15 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the surface of the nanocrystalline powder is coated with a 5-10 nm silicon oxide insulating layer.

[0039] Example 16 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the resin mixture is silicone resin.

[0040] Example 17 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that silicone resin is used as the resin mixture.

[0041] Example 18 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the epoxy resin content is 0.5 wt %.

[0042] Example 19 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the epoxy resin content is 1.5 wt %.

[0043] Example 20 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that a nanofiller accounting for 12 wt% of the mass of the resin mixture is dispersed in the resin mixture, and the nanofiller is AlN with a particle size of 18-40 nm.

[0044] Example 21 A preparation method of a high-frequency power inductor material: The difference from Example 1 is that a nanofiller accounting for 12 wt% of the mass of the resin mixture is dispersed in the resin mixture, and the nanofiller is BN with a particle size of 18-40 nm.

[0045] Example 22 A preparation method of a high-frequency power inductor material: The difference from Example 1 is that a nanofiller accounting for 12 wt% of its mass is dispersed in the resin mixture, and the nanofiller is Si3N4 with a particle size of 18-40 nm.

[0046] Comparative Example Comparative Example 1 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that the Fe content in the Fe-based nanocrystals is increased to 85wt%, and Si and Co are compressed to 8wt% and 5wt% respectively.

[0047] Comparative Example 2 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that Co (0wt%) is completely removed from the Fe-based nanocrystals, Fe is increased to 75wt%, Si 12wt%, Mn 2.5wt%, B 5wt%, and Cu 1wt%.

[0048] Comparative Example 3 A method for preparing a high-frequency power inductor material: The difference from Example 1 is that a traditional Fe-Si-B amorphous alloy (composition Fe 78wt%, Si 10wt%, B 12wt%) is used, and no nanocrystallization treatment is performed (grain size >100nm, non-nanocrystalline structure).

[0049] Performance testing 1. Inductance and Equivalent Series Resistance (ESR) The inductance (L) and equivalent series resistance (ESR) of the samples were measured using a Keysight E4980A precision LCR meter at a frequency of 10 MHz and an excitation voltage of 100 mV. The measurement was repeated three times for each sample and the average value was taken.

[0050] 2. Loss density The active power loss (P) of the sample was measured by Chroma17010 power analyzer under 10 MHz, 10 A sinusoidal AC current. 2 h=3.14×(5mm) 2 ×5mm=392.5mm 3 =3.925×10 -7 m 3 ), calculate the loss density.

[0051] 3. Curie temperature (T_c) A NETZSCH STA449F3 thermal magnetic analyzer was used to increase the temperature from room temperature to 600°C at a heating rate of 10°C / min. The temperature at which the magnetic permeability dropped to 50% of the room temperature value was measured as the Curie temperature.

[0052] 4.100kHz magnetic permeability (μ) The complex permeability of the sample was measured using a HIOKI IM3570 impedance analyzer at 100 kHz and a 10 mT excitation magnetic field, and the real part was taken as the effective permeability.

[0053] Table 1 Test data Combining Example 1 with Comparative Example 1 and Table 1, it can be seen that in Comparative Example 1, the Fe content is increased to 85wt% (exceeding the upper limit of 78.5wt% in the claim), resulting in an imbalance in the Si / Co ratio (Si is reduced to 8wt% and Co is reduced to 5wt%). The test data shows that its equivalent series resistance (ESR) surges from 110mΩ in Example 1 to 180mΩ, and the loss density increases from 0.75W / cm 3 Increased to 1.10W / cm 3 (46.7% increase), the 100kHz magnetic permeability dropped from 36,000 to 25,000, and the Curie temperature dropped from 520°C to 450°C. This is because the excessively high Fe content causes the material's resistivity to decrease (increased conductive paths), while the insufficient Co content weakens the optimization effect of the magnetic domain wall motion resistance, ultimately exacerbating eddy current losses and hysteresis losses. This verifies the key role of the upper limit of Fe content in claim 1 on high-frequency performance.

[0054] Combining Example 1 and Comparative Example 2 with Table 1, it can be seen that Comparative Example 2 completely removes Co (0 wt%) and maintains the composition balance by increasing Fe to 75 wt%. The results show that its loss density reaches 1.00 W / cm 3 The Curie temperature dropped sharply to 380°C (a decrease of 26.9%) compared to Example 1, and the 100kHz permeability dropped to 28,000. Analysis shows that Co, as a key component, can refine the magnetic domain structure and reduce the resistance to domain wall movement. After its deletion, the proportion of hysteresis loss increased from 40% in Example 1 to 65%. The decrease in Curie temperature leads to the deterioration of magnetic performance stability in high-temperature environments, directly proving the irreplaceable role of Co in suppressing high-frequency hysteresis loss.

[0055] Combining Example 1 and Comparative Example 3 with Table 1, it can be seen that Comparative Example 3 uses a traditional Fe-Si-B amorphous alloy (grain size > 100 nm) without nanocrystallization, and its loss density is as high as 1.30 W / cm 3 (1.73 times that of Example 1), the 100kHz magnetic permeability is only 20,000 (55.6% of that of Example 1), and the inductance drops to 2.2μH (lower than 2.8μH in Example 1). Because the amorphous structure lacks the grain refinement effect brought by nanocrystallization, it cannot effectively segment the eddy current path and the magnetic domain wall movement resistance is large, resulting in a simultaneous increase in eddy current loss and hysteresis loss, highlighting the core role of the nanocrystalline structure in high-frequency low-loss.

[0056] Combining Examples 1-3 with Table 1, it can be seen that Examples 1-3 respectively select the middle value (Fe70wt%), lower limit (Fe59wt%), and upper limit (Fe78.5wt%) of the composition range of Claim 1. The test data show that the inductance value is 2.7-2.9μH and the loss density is 0.70-0.78W / cm 3 , 100kHz magnetic permeability fluctuates between 34000-36000, both meeting the requirements of high-frequency scenarios. Among them, Fe59wt% (Example 2) has a slightly higher resistivity and a slightly lower loss density (0.70W / cm) due to the higher Si / Co content (Si15wt%, Co15wt%). 3 ); Fe 78.5wt% (Example 3) approaches the upper limit of the composition, resulting in a slight decrease in magnetic permeability but still remaining within a reasonable range. The results demonstrate that the composition range defined in Claim 1 ensures stable overall performance at high frequencies, and different ratios can be flexibly adjusted based on actual requirements (such as saturation magnetic induction intensity or resistivity).

[0057] Combining Examples 1, 4-7, and Table 1, it can be seen that Examples 4-7 significantly reduced high-frequency parasitic capacitance by increasing the interlayer spacing (1-2.5 times the wire diameter) and the boundary distance (0.5-2 times the wire diameter). Compared with Example 1, when the interlayer spacing is 2 times the wire diameter (Example 5), the ESR is reduced from 110mΩ to 92mΩ (a decrease of 16.4%), and the loss density is reduced to 0.60W / cm 3 (20% decrease); when the boundary distance is 2 times the wire diameter (Example 7), the ESR is further reduced to 95mΩ, and the loss density is 0.63W / cm 3 This is because increasing the spacing weakens the electric field coupling between windings, reduces the interlayer capacitance (the measured parasitic capacitance drops from 18pF to 12pF), and reduces the leakage loss caused by edge magnetic field distortion, verifying the optimization effect of the structural parameters in claim 2 on high-frequency electromagnetic coupling characteristics.

[0058] Combining Examples 1, 8-12 and Table 1, it can be seen that in Examples 8-12, a FeSiAl alloy flaky magnetic isolation layer (thickness 20-80 μm, particle diameter 30-100 μm) is introduced between the electrode and the magnet. Compared with Example 1, the loss density is reduced to a minimum of 0.53 W / cm 3 (Example 10, 75μm thickness), ESR dropped to 82mΩ (25.5% reduction). Among them, the comprehensive performance was the best when the thickness was 50μm (Example 8) (loss density 0.55W / cm 3 ), too thin (25μm) or too thick (75μm) both result in slightly increased losses due to incomplete magnetic shielding or increased parasitic parameters; a particle diameter of 60μm (Example 8) reduces magnetic leakage flux by 28%, superior to 35μm (Example 11) or 95μm (Example 12). The results demonstrate that the magnetic isolation layer material composition and structural parameters defined in Claims 3-4 can effectively block the magnetic leakage path between the electrode and the magnet, reduce stray magnetic field interference, and achieve precise control of magnetic leakage losses at high frequencies.

[0059] Combining Examples 1 and 13 with Table 1, it can be seen that in Example 13, the particle size of the Fe-based nanocrystalline powder is refined from 10 μm to 1-6 μm, and the grain size is controlled from 50 nm to 10-30 nm. Its 100 kHz magnetic permeability is increased to 40,000 (1.11 times that of Example 1), and the loss density is reduced to 0.62 W / cm 3 The inductance increased to 2.9μH (a 17.3% decrease). This is due to the ultrafine powder and nanocrystalline structure (e.g., 15nm grains) reducing the resistance to domain wall movement and segmenting the eddy current path, resulting in a 25% and 18% reduction in hysteresis and eddy current losses, respectively. The data demonstrates that the limited powder and grain sizes in Claim 5 are the core technical features that enhance the material's high-frequency permeability and reduce losses.

[0060] Combining Examples 1, 14-15, and Table 1, it can be seen that in Examples 14-15, a 5-10 nm aluminum oxide / silicon oxide insulating layer is prepared on the surface of the nanocrystalline powder. Compared with Example 1, the ESR is reduced to 85 mΩ and 86 mΩ, respectively (a decrease of 22.7%-21.8%), and the loss density is reduced to 0.55-0.56 W / cm 3 (A decrease of 25.3%-25.8%). The insulating layer physically isolates and blocks the conductive pathways between particles, increasing the material resistivity from 75μΩ·cm to over 90μΩ·cm and reducing the eddy current loss ratio from 60% to approximately 42%. The two coating materials (aluminum oxide / silicon oxide) have similar effects, verifying the universality and effectiveness of the surface insulating layer design in claim 6 in suppressing high-frequency eddy current losses.

[0061] Combining Examples 1, 16-22 and Table 1, it can be seen that Examples 16-22 adjust the resin type (epoxy resin, silicone resin, silicone resin) and add nanofillers (AlN, BN, Si3N4). The results show that different resin types (Examples 16-17) have little effect on the loss (loss density 0.73-0.74 W / cm 3 ), but the Curie temperature is increased to 535-540°C, reflecting the compatibility of the material with high temperature resistance; after adding 12wt% nanofiller (Examples 20-22), the ESR is reduced to 99-101mΩ (a decrease of 8.2%-10% compared with Example 1), and the loss density is reduced to 0.62-0.64W / cm 3 (A decrease of 14.7%-17.3%), and the thermal conductivity of the magnet increased by about 15%. This shows that the inter-particle insulation layer composed of the resin mixture and nanofiller in claims 7-8 can not only block eddy current conduction through the insulating resin, but also utilize high thermal conductivity nanofillers (such as BN thermal conductivity >300W / m·K) to improve heat dissipation capacity, achieving dual optimization of "electrical insulation and thermal conduction", and meeting the heat dissipation and loss control requirements in high-frequency and high-current scenarios.

[0062] This specific embodiment is merely an explanation of the present application and is not a limitation of the present application. After reading this specification, those skilled in the art may make non-creative modifications to the present embodiment as needed, but as long as they are within the scope of the claims of the present application, they are protected by the patent law.

Claims

1. A high-frequency power inductor material, characterized in that: including magnets and windings; The windings are staggered and distributed inside the magnet, and electrodes are formed at both ends of the windings; The magnet is composed of Fe-based nanocrystalline material, and its components are as follows by weight percentage: Fe: 59.0wt%-78.5wt%; Si: 10wt%-15wt%; Co: 7wt%-15wt%; Mn: 1wt%-3.5wt%; B: 3wt%-6wt%; Cu: 0.5wt%-1.5wt%.

2. The high-frequency power inductor material according to claim 1, characterized in that: The interlayer spacing of the winding is 1 to 2.5 times the winding wire diameter, and the spacing between the outermost layer of the winding and the magnet is 0.5 to 2 times the wire diameter; a magnetic isolation material layer is provided between the electrode portion of the winding extending out of the magnet and the magnet, and its thickness is 20 to 80 μm.

3. The high-frequency power inductor material according to claim 2, characterized in that: The magnetic isolation material is a FeSiAl flake alloy, and its composition by weight percentage is as follows: Fe: 87-88wt% Si: 6.5-7.5wt% Al: 3.5-6.5wt%.

4. The high-frequency power inductor material according to claim 3, characterized in that: The flaky alloy particles have a thickness of 1-3 μm and a diameter of 30-100 μm.

5. The high-frequency power inductor material according to claim 1, characterized in that: The powder particle size of the Fe-based nanocrystals is 1-6 μm, and the grain size is 10-30 nm.

6. The high-frequency power inductor material according to claim 5, characterized in that: The surface of the nanocrystalline powder is coated with an aluminum oxide or silicon oxide insulating layer of 5-10 nm.

7. The high-frequency power inductor material according to claim 1, characterized in that: The magnet contains 0.5wt%-1.5wt% of a resin mixture, and the resin mixture is selected from one or more of epoxy resin, organic silicon resin, and silicone resin.

8. The high-frequency power inductor material according to claim 7, characterized in that: The resin mixture is dispersed with nanofillers accounting for 10wt%-15wt% of the resin mixture's mass, wherein the nanofillers are one or more of AlN, BN, and Si3N4, and have a particle size of 18-40nm.

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