Multiphase coupling inductance material

Abstract

The invention relates to a multi-phase coupling inductance material, and relates to the technical field of inductance elements, the multi-phase coupling inductance material comprises a magnet, a first winding and a second winding, the first winding forms an upper and lower electrode structure in an up and down lead-out mode, the second winding is arranged on one side of the first winding, and the second winding and the first winding form a coupling structure; the second winding extends out of the magnet to form an electrode; the magnet is composed of iron-based alloy and mixed powder of Cr powder and Al powder, and the iron-based alloy comprises, by mass, 1%-3% of Si, 25%-35% of Ni, 1.5%-4% of Al, 0.5%-2% of V and the balance iron. The multi-phase structure coupling is adopted to reduce the requirement of the inductor on the magnetic conductivity, and the power consumption and saturation of the material are balanced, so that the requirements of a power device on high power and low loss are met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of inductive elements, in particular to a multi-phase coupled inductive material. BACKGROUND

[0002] With the rapid development of science and technology, GPΜ has made great progress, and the power density has been significantly improved from hundreds of watts to thousands of watts, and the current density has also increased significantly. This development makes the inductor play an increasingly important role in the application of high power and high current, and puts forward higher requirements for the performance of inductive materials and structures. As an important element in the circuit, inductors are widely used in various electronic devices and power systems, and their performance directly affects the stability and efficiency of the entire system. In the background of continuous innovation of modern electronic technology, the development of inductive technology plays a crucial role in promoting the miniaturization and high efficiency of electronic products. Inductive materials can realize energy storage and conversion, ensure the normal operation of the circuit, and provide strong support for the development of many fields.

[0003] In the past, in order to cope with similar high-current and high-power working conditions, the industry usually adopts specific technical means. For the selection of magnetic materials for high-power inductors, most of them tend to use alloy materials as the main magnetic material. This choice is based on the fact that alloy materials have certain magnetic properties and can meet the working requirements of inductors to a certain extent. At the same time, due to the large current, in order to adapt to this situation, the copper wire generally adopts a single coil structure. This single coil structure is relatively simple, easy to manufacture and install, and can withstand a large current within a certain range. These conventional means effectively solve some problems in the application of inductors within a certain period of time and become a commonly used solution in the industry.

[0004] However, the existing technical means have obvious defects. On the one hand, the alloy material system currently used has an exponential relationship between magnetic hysteresis loss and magnetic induction intensity. In the case of large current, the magnetic induction intensity of the magnet increases, resulting in a sharp rise in magnetic hysteresis loss, which significantly increases the loss of the material under large current, which seriously affects the application effect of the product. On the other hand, the single coil structure has high requirements for the magnetic permeability of the material, and the current alloy material system is difficult to meet this requirement, which is prone to material saturation, resulting in the saturation performance of the material failing to meet the design requirements, thereby limiting the further application of inductors in high-current and high-power scenarios, and thus needs to be improved. SUMMARY

[0005] In order to improve the performance of inductive materials, the present application provides a multi-phase coupled inductive material.

[0006] The multi-phase coupled inductive material provided by the present application adopts the following technical scheme: A multi-phase coupled inductance material comprises a magnet, a first winding and a second winding, the first winding forms an up-down electrode structure by up-down leading, the second winding is arranged on one side of the first winding and forms a coupling structure with the first winding, and the second winding extends out of the magnet to form an electrode; the magnet is composed of mixed powder of iron-based alloy and Cr powder and Al powder, the iron-based alloy contains the following components with mass percentage: 1-3% Si, 25-35% Ni, 1.5-4% Al, 0.5-2% V, and the balance is iron.

[0007] Through material ratio control and device structure collaborative innovation, in the material design, the silicon element improves the bulk resistivity to suppress the eddy current, and the formation of the iron-nickel phase effectively reduces the hysteresis loss; aluminum and vanadium are enriched on the surface of the particles, and the chromium element generates a uniform high-temperature bonding phase in the heat treatment, and the saturation magnetic induction strength is enhanced by the distributed micro air gap; the multi-phase coupling structure is adopted, the dependence on single magnetic permeability is reduced by electromagnetic field optimization, the power consumption and saturation characteristics of the magnetic core are balanced; this breakthrough in material and structure dimensions meets the requirements of high power density power electronic equipment for strong current carrying capacity and low energy loss.

[0008] Preferably, a winding gap isolation layer is arranged between the first winding and the second winding.

[0009] The winding gap isolation layer improves the reliability and electromagnetic performance of the device through the dual effects of physical isolation and electrical insulation; the isolation layer can block the direct contact between the first winding and the second winding, which not only eliminates the risk of creepage caused by potential difference, but also suppresses the parasitic capacitance effect caused by high-frequency coupling, and its high thermal conductivity characteristic establishes an independent heat dissipation channel for the winding, effectively alleviating the thermal coupling effect under large current conditions; this design realizes breakthroughs in key indicators such as high voltage isolation, temperature balance and electromagnetic interference on the premise of maintaining the original magnetic coupling efficiency, and can meet the stringent requirements of electrical safety and thermal management of multi-phase inductance in high power density power modules.

[0010] Preferably, the winding gap isolation layer comprises spherical NiZn ferrite powder with a particle size of 0.05-0.15 μm.

[0011] The nanoscale spherical NiZn ferrite powder forms a dense stacking structure in the isolation layer, its inherent high resistivity characteristic can suppress the leakage current between the electrodes, and the magnetic permeability regulation capability of the ferrite itself optimizes the local magnetic circuit of the winding coupling area, reducing high-frequency eddy current loss; the spherical geometry can make the particles uniformly dispersed, which not only eliminates the electric field concentration point to enhance the insulation reliability, but also precisely suppresses the parasitic capacitance effect by constructing a gradient dielectric constant interface.

[0012] Preferably, the width of the winding gap isolation layer is 0.1-0.15 μm.

[0013] The width of the winding gap isolation layer ensures that the NiZn ferrite particles form a continuous and dense insulating barrier to block the creepage path, and matches the attenuation characteristics of the high-frequency magnetic field in the winding gap, effectively suppressing the eddy current loss caused by the leakage of the edge magnetic flux; the size is well matched with the particle size of the ferrite particles, and under the premise of maintaining the low dielectric constant characteristics, a uniform electric field distribution is constructed to eliminate the risk of partial discharge.

[0014] Preferably, the length of the second winding is 50-100% of the length of the first winding.

[0015] The differentiated winding length design makes the main first winding completely cover the core magnetic flux path to maximize the inductance energy storage density, while the length of the secondary second winding is adapted to constrain the edge magnetic field diffusion area, effectively suppressing the eddy current loss and proximity effect caused by magnetic flux leakage; at the same time, the asymmetric heat source layout formed by the length difference naturally establishes a gradient heat dissipation channel, reducing the hotspot temperature at the winding junction; this structural design synchronously improves the loss control capability and thermal reliability under high-frequency working conditions while ensuring efficient transmission of electromagnetic energy.

[0016] Preferably, the second winding forms an electrode with a gap of 0.2-0.5mm from the electrode formed by the first winding.

[0017] Through specific size design of the electrode gap, a good balance between high-voltage insulation safety and electromagnetic heat management efficiency is achieved; the micro-scale air layer in the gap acts as a natural dielectric barrier to block the high-voltage creepage risk between electrodes, while inducing uniform distribution of the edge electric field to eliminate the risk of partial discharge; the gap structure further builds a forced convection heat dissipation channel between the electrodes, reducing the heat accumulation at the electrode junction area under high-current working conditions; and the precisely controlled gap depth suppresses the electrode electromagnetic coupling oscillation caused by high-frequency switching transients, ensuring signal transmission purity; this design makes the advantages of asymmetric winding layout fully play, providing threefold protection of electrode insulation reliability, thermal distribution uniformity and electromagnetic compatibility for high-power density modules under the premise of maintaining the coupling efficiency of the magnetic circuit, improving the life of high-voltage high-frequency inductors under extreme working conditions.

[0018] Preferably, the particle size of the iron-based alloy is 5-15μm, and the iron-based alloy accounts for 98.5-99.5% of the mass of the mixed powder.

[0019] The iron-based alloy particles with the above particle size distribution can form a closely packed magnetic flux conduction network, and the optimized grain boundary proportion can reduce hysteresis loss, while the micron-level particle size accurately matches the penetration depth of the high-frequency alternating magnetic field, and the eddy current strength is weakened by increasing the grain boundary scattering effect; a high proportion of iron-based alloy forms a continuous matrix for magnetic flux conduction, which guarantees the core characteristics of high saturation magnetic density and low hysteresis loss; a small amount of Cr / Al mixed powder is distributed on the alloy particle interface to form a nanoscale resistance network layer, which inhibits high-frequency eddy current by increasing the depth of the grain boundary potential barrier without hindering the main magnetic circuit, so that the magnet has excellent soft magnetic properties and low eddy current loss in a wide frequency range.

[0020] Preferably, the surface of the iron-based alloy comprises a first layer of cladding and a second layer of cladding, the first layer of cladding comprises aluminum oxide, titanium oxide, chromium oxide, iron oxide, and has a thickness of 10-50 nm; the second layer of cladding comprises silicon oxide, aluminum oxide, and has a thickness of 5-20 nm.

[0021] The first layer of multi-element oxide constructs a dense grain boundary passivation film, which accurately regulates the magnetic domain wall displacement resistance to reduce hysteresis loss while suppressing the intrinsic eddy current of the alloy; the second layer of high insulation composite layer forms a continuous dielectric barrier to block the inter-particle leakage current and inhibit the dielectric polarization loss caused by high-frequency alternating electric field; this gradient cladding structure makes each alloy particle a functional unit with self-balanced magnetic-electric-thermal properties, which improves the nanoscale insulation strength while maintaining high magnetic permeability, providing core material support for the high-frequency and high-efficiency operation of the multi-phase coupled inductor in extreme environments such as humidity and salt spray.

[0022] Preferably, the particle size of the Cr powder and the Al powder is 0.5-1.0 μm, and the surface of the Cr powder and the Al powder has a self-formed oxide layer with a thickness of 50-100 nm.

[0023] The micron-level particle size of the Cr powder and the Al powder can match the grain boundary gap of the iron-based alloy, and the dense oxide layer grown in situ on the surface forms a continuous nanoscale insulation network, which blocks the grain boundary electron migration through quantum tunneling effect to deeply suppress high-frequency eddy current; at the same time, the optimized oxide layer thickness minimizes the pinning effect on the magnetic domain wall displacement while guaranteeing the insulation strength, avoiding abnormal increase of hysteresis loss; this additive particle wrapped with self-grown oxide makes the magnet have anisotropic resistance characteristics, maintaining high magnetic permeability in the parallel magnetic circuit direction and cutting off eddy current in the vertical grain boundary direction, which improves the limit power density of the multi-phase coupled inductor under high-frequency working conditions.

[0024] Preferably, the surface of the mixed powder of the iron-based alloy, the Cr powder and the Al powder is treated by a resin treatment agent to obtain a resin cladding layer, the resin treatment agent comprises one of epoxy resin, phenolic resin and silicone resin, and the thickness of the resin cladding layer is 100-200 nm.

[0025] The nanoscale resin coating layer constructs a continuous flexible sealing network outside the mixed powder, prevents electrochemical corrosion by blocking the penetration of moisture and pollutants through seamless bonding of polymer chains, optimizes the high-frequency electric field distribution to suppress dielectric loss by using the intrinsic low dielectric constant property of organic resin, and matches the elastic modulus with the thermal expansion coefficient of the metal powder to maintain the integrity of the coating layer during temperature changes, eliminating the risk of insulation failure caused by stress cracking. This design enables the magnet to maintain low eddy current loss and stable permeability characteristics in harsh environments such as humidity, salt spray, and high and low temperature cycling.

[0026] In summary, the present application includes at least one of the following beneficial technical effects: 1. Through material ratio control and device structure collaborative innovation, in material design, silicon element improves bulk resistivity to suppress eddy current, while iron-nickel phase formation effectively reduces hysteresis loss; aluminum and vanadium are enriched on the particle surface, which cooperates with chromium element to generate uniform high-temperature bonding phase during heat treatment, and the saturation magnetic induction strength is enhanced by distributed micro air gap; a multi-phase coupling structure is adopted to reduce the dependence on single permeability by optimizing the electromagnetic field, so that the power consumption and saturation characteristics of the magnetic core are balanced; this breakthrough in both material and structure dimensions meets the requirements of high power density power electronic equipment for strong current carrying capacity and low energy loss.

[0027] 2. The winding isolation layer improves the reliability and electromagnetic performance of the device through physical isolation and electrical insulation; the isolation layer can block the direct contact between the first winding and the second winding, eliminating the risk of creepage caused by potential difference and suppressing the parasitic capacitance effect caused by high-frequency coupling, and its high thermal conductivity characteristic establishes an independent heat dissipation channel for the winding, effectively alleviating the thermal coupling effect under high current conditions; this design breaks through in key indicators such as high voltage isolation, temperature equalization, and electromagnetic interference while maintaining the original magnetic coupling efficiency, meeting the stringent requirements of high power density power modules for electrical safety and thermal management of multi-phase inductors. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 Structure cross section of the present application examples 1-3 and comparative example 3 Figure 1 ; Figure 2 Structure cross section of the present application examples 1-3 and comparative example 3 Figure 2 ; Figure 3 Structure cross section of the present application comparative example 1 Figure 4 Structure cross section of the present application comparative example 2 BRIEF DESCRIPTION OF DRAWINGS: 1, magnet; 2, first winding; 3, second winding; 4, winding isolation layer; 5, magnetic isolation material. DETAILED DESCRIPTION

[0029] The application discloses a multi-phase coupling inductance material. Raw materials used in the application can be obtained from the market except for special instructions. The application is further described in detail in combination with examples and drawings. The application is described in combination with drawings, Figure 1 and Figure 2 The application discloses a multi-phase coupling inductance material. Raw materials used in the application can be obtained from the market except for special instructions. The application is further described in detail in combination with examples and drawings. The multi-phase coupling inductance material of the application is shown in the cross-sectional view of the application examples 1-3 and the comparative example 3. The multi-phase coupling inductance is composed of a magnet 1, a first winding 2 and a second winding 3. The first winding 2 forms an upper and lower electrode structure by the upper and lower leading mode. The second winding 3 is arranged on one side of the first winding 2 and forms a coupling structure with the first winding 2. The second winding 3 extends out of the magnet 1 to form an electrode. The gap between the first winding 2 and the second winding 3 is provided with a winding interlayer 4 which is isolated by 0.05-0.15 μm spherical NiZn ferrite powder. The width of the winding interlayer 4 is 0.1-0.15 μm. The length of the second winding 3 is 50-100% of the length of the first winding 2. There is a gap of 0.2-0.5 mm between the electrode formed by the second winding 3 and the electrode formed by the first winding 2. The magnet 1 is composed of mixed powder of iron-based alloy and Cr powder and Al powder. The iron-based alloy contains the following components with mass percentage: 1-3% Si, 25-35% Ni, 1.5-4% Al, 0.5-2% V, and the balance is iron. The particle size of the iron-based alloy is 5-15 μm. The mass percentage of the iron-based alloy in the mixed powder is 98.5-99.5%. The surface of the iron-based alloy includes a first layer of coating and a second layer of coating. The first layer of coating includes aluminum oxide, titanium oxide, chromium oxide and iron oxide with a thickness of 10-50 nm. The second layer of coating includes silicon oxide and aluminum oxide with a thickness of 5-20 nm. The particle size of the Cr powder and the Al powder is 0.5-1.0 μm. The surface of the Cr powder and the Al powder has an oxide layer formed by itself with a thickness of 50-100 nm. The surface of the mixed powder of the iron-based alloy, the Cr powder and the Al powder is treated by a resin treatment agent to obtain a resin coating layer. The resin treatment agent includes one of epoxy resin, phenolic resin and silicone resin. The thickness of the resin coating layer is 100-200 nm.

[0030] Example 1 A multi-phase coupling inductor is composed of a magnet, a first winding and a second winding. The first winding forms an upper and lower electrode structure by leading out from the upper and lower sides, and the second winding is arranged on one side of the first winding and forms a coupling structure with the first winding, and the second winding extends out of the magnet to form an electrode. A winding isolation layer is arranged between the first winding and the second winding, which is isolated by 0.1 μm spherical NiZn ferrite powder, and the width of the winding isolation layer is 0.1 μm. The length of the second winding is 50% of the length of the first winding, and there is a gap of 0.2 mm between the electrode formed by the second winding and the electrode formed by the first winding. The magnet is composed of mixed powder of Fe-based alloy and Cr powder, Al powder, and the Fe-based alloy contains the following components with mass percentage: 56% Fe, 3% Si, 35% Ni, 4% Al, 2% V. The particle size of the Fe-based alloy is 15 μm, and the Fe-based alloy accounts for 98.5% of the mass of the mixed powder. The surface of the Fe-based alloy includes a first layer of cladding layer and a second layer of cladding layer, which are obtained by atomic deposition, and the first layer of cladding layer includes the following components with mass percentage: 15% aluminum oxide, 15% titanium oxide, 25% chromium oxide, 55% iron oxide, and the thickness is 50 nm; the second layer of cladding layer includes the following components with mass percentage: 70% silicon oxide, 30% aluminum oxide, and the thickness is 20 nm. The particle size of the Cr powder and the Al powder is 1.0 μm, and the surface of the Cr powder and the Al powder has an oxide layer formed by itself, and the thickness of the oxide layer is 100 nm, and the mass ratio of the Cr powder and the Al powder is 1:1. The surface of the mixed powder of the Fe-based alloy, the Cr powder and the Al powder is treated by a resin treatment agent to obtain a resin cladding layer, and the resin treatment agent is epoxy resin, and the thickness of the resin cladding layer is 200 nm.

[0031] Example 2 A multi-phase coupling inductor is composed of a magnet, a first winding and a second winding. The first winding forms an upper and lower electrode structure by leading out from the upper and lower sides, and the second winding is arranged on one side of the first winding and forms a coupling structure with the first winding, and the second winding extends out of the magnet to form an electrode. A winding isolation layer is arranged between the first winding and the second winding, which is isolated by 0.1 μm spherical NiZn ferrite powder, and the width of the winding isolation layer is 0.12 μm. The length of the second winding is 80% of the length of the first winding, and there is a gap of 0.35 mm between the electrode formed by the second winding and the electrode formed by the first winding. The magnet is composed of mixed powder of Fe-based alloy and Cr powder and Al powder, and the Fe-based alloy contains the following components with mass percentage: 63.7% Fe, 2% Si, 30% Ni, 2.8% Al, and 1.5% V. The particle size of the Fe-based alloy is 9 μm, and the Fe-based alloy accounts for 99% of the mass of the mixed powder. The surface of the Fe-based alloy includes a first coating layer and a second coating layer, which are obtained by atomic deposition. The first coating layer contains the following components with mass percentage: 15% aluminum oxide, 15% titanium oxide, 25% chromium oxide, and 55% iron oxide, and the thickness is 25 nm; the second coating layer contains the following components with mass percentage: 70% silicon oxide and 30% aluminum oxide, and the thickness is 12 nm. The particle size of the Cr powder and the Al powder is 0.7 μm, and the surface of the Cr powder and the Al powder has an oxide layer formed by itself, and the thickness of the oxide layer is 80 nm, and the mass ratio of the Cr powder to the Al powder is 3:1. The surface of the mixed powder of the Fe-based alloy, the Cr powder and the Al powder is treated by a resin treatment agent to obtain a resin coating layer, and the resin treatment agent is silicone resin, and the thickness of the resin coating layer is 150 nm.

[0032] Example 3 A multi-phase coupling inductor is composed of a magnet, a first winding and a second winding. The first winding forms an upper and lower electrode structure by leading out from the upper and lower sides, and the second winding is arranged on one side of the first winding and forms a coupling structure with the first winding, and the second winding extends out of the magnet to form an electrode. A winding isolation layer is arranged between the first winding and the second winding, which is isolated by 0.1 μm spherical NiZn ferrite powder, and the width of the winding isolation layer is 0.15 μm. The length of the second winding is 100% of the length of the first winding, and there is a gap of 0.5 mm between the electrode formed by the second winding and the electrode formed by the first winding. The magnet is composed of mixed powder of Fe-based alloy and Cr powder, Al powder, and the Fe-based alloy contains the following components with mass percentage: 72% Fe, 1% Si, 25% Ni, 1.5% Al, 0.5% V. The particle size of the Fe-based alloy is 5 μm, and the Fe-based alloy accounts for 99.5% of the mass of the mixed powder. The surface of the Fe-based alloy includes a first layer of cladding layer and a second layer of cladding layer, which are obtained by atomic deposition, and the first layer of cladding layer includes the following components with mass percentage: 15% aluminum oxide, 15% titanium oxide, 25% chromium oxide, 55% iron oxide, and the thickness is 10 nm; the second layer of cladding layer includes the following components with mass percentage: 70% silicon oxide, 30% aluminum oxide, and the thickness is 5 nm. The particle size of the Cr powder and the Al powder is 0.5 μm, and the surface of the Cr powder and the Al powder has an oxide layer formed by itself, and the thickness of the oxide layer is 50 nm, and the mass ratio of the Cr powder and the Al powder is 2:1. The surface of the mixed powder of the Fe-based alloy, the Cr powder and the Al powder is treated by a resin treatment agent to obtain a resin cladding layer, and the resin treatment agent is phenolic resin, and the thickness of the resin cladding layer is 100 nm.

[0033] Comparative Example 1 A multi-phase coupling inductor is composed of a magnet 1, a first winding 2 and a second winding 3. The first winding 2 forms an upper and lower electrode structure by leading out from the upper and lower sides, and the second winding 3 is arranged on one side of the first winding 2 and forms a coupling structure with the first winding 2, and the second winding 3 extends out of the magnet 1 to form an electrode. There is no obvious spacing between the first winding 2 and the second winding 3, and the spacing between the outermost winding and the magnet 1 is 0.5 times the wire diameter of the winding. The electrode part of the first winding 2 and the second winding 3 extending out of the magnet 1 is provided with a magnetic separation material 5 between the magnet 1, and the thickness of the magnetic separation material 5 is 20μm. The magnetic separation material 5 is a FeSiAl sheet material, which contains the following components with the mass percentage: 88% Fe, 7.2% Si, 4.8% Al. The thickness of the FeSiAl sheet material is 1-3μm, and the diameter of the sheet material is 30-100μm. The magnet 1 is composed of Fe-based microcrystals, which contain the following components with the mass percentage: 59% Fe, 15% Si, 15% Co, 3.5% Mn, 6% B, 1.5% Cu. The particle size of the Fe-based microcrystals is 1-6μm, and the surface of the Fe-based microcrystals is coated with an alumina layer of 10nm. The grain size of the Fe-based microcrystals is 10nm, and the Fe-based microcrystals contain a resin mixture, which accounts for 0.5% of the mass of the Fe-based microcrystals. The resin mixture includes epoxy resin and 10% AlN by mass of the epoxy resin, and the particle size of the AlN is 40nm.

[0034] Comparative Example 2 A multi-phase coupled inductor is composed of a magnetic body 1, a first winding 2 and a second winding 3. The first winding 2 forms an upper and lower electrode structure by leading out from the upper and lower sides, and the second winding 3 is arranged on one side of the first winding 2 and forms a coupling structure with the first winding 2, and the second winding 3 extends out of the magnetic body 1 to form an electrode. A winding separation layer 4 is arranged in the gap between the first winding 2 and the second winding 3, and the winding separation layer 4 is separated by 0.1 μm spherical NiZn ferrite powder, and the width of the winding separation layer 4 is 0.1 μm. The distance between the windings of the first winding 2 and the second winding 3 is 2.5 times the wire diameter of the winding, and the distance between the outermost winding and the magnetic body 1 is 0.5 times the wire diameter. The electrode part of the first winding 2 and the second winding 3 extending out of the magnetic body 1 is separated from the magnetic body 1 by a magnetic separation material 5, and the thickness of the magnetic separation material 5 is 20 μm. The magnetic separation material 5 is a FeSiAl sheet material, which contains the following components in mass percentage: 88% Fe, 7.2% Si, 4.8% Al. The thickness of the FeSiAl sheet material is 1-3 μm, and the diameter of the FeSiAl sheet material is 30-100 μm. The magnetic body 1 is composed of Fe-based crystallites, which contain the following components in mass percentage: 59% Fe, 15% Si, 15% Co, 3.5% Mn, 6% B, 1.5% Cu. The particle size of the Fe-based crystallites is 1-6 μm, the grain size of the Fe-based crystallites is 10 nm, the Fe-based crystallites contain a resin mixture, the mass of the resin mixture accounts for 0.5% of the Fe-based crystallites, and the resin mixture includes epoxy resin and 10% AlN of the mass of the epoxy resin, and the particle size of the AlN is 40 nm.

[0035] Comparative Example 3 A multi-phase coupled inductor is composed of a magnetic body, a first winding and a second winding. The first winding forms an upper and lower electrode structure by leading out from the upper and lower sides, and the second winding is arranged on one side of the first winding and forms a coupling structure with the first winding, and the second winding extends out of the magnetic body to form an electrode. A winding separation layer is arranged in the gap between the first winding and the second winding, and the winding separation layer is separated by 0.1 μm spherical NiZn ferrite powder, and the width of the winding separation layer is 0.1 μm. The distance between the windings of the first winding and the second winding is 2.5 times the wire diameter of the winding, and the distance between the outermost winding and the magnetic body is 0.5 times the wire diameter. The magnetic body is composed of Fe-based crystallites, which contain the following components in mass percentage: 59% Fe, 15% Si, 15% Co, 3.5% Mn, 6% B, 1.5% Cu. The particle size of the Fe-based crystallites is 1-6 μm, the surface of the Fe-based crystallites has a 10 nm aluminum oxide coating layer, the grain size of the Fe-based crystallites is 10 nm, the Fe-based crystallites contain a resin mixture, the mass of the resin mixture accounts for 0.5% of the Fe-based crystallites, and the resin mixture includes epoxy resin and 10% AlN of the mass of the epoxy resin, and the particle size of the AlN is 40 nm.

[0036] Performance detection test The performance of the cured product was evaluated, wherein the product size was 2.5 mm long*2.0 mm wide*2.0 mm high, 4-phase coupling structure, the inductance value L and the saturation current value Isat of the sample were tested under the test conditions of WK3260B at 1V / 700 kHz; the loss of the product was tested under the conditions of SY-8218C at 700 kHz sinusoidal wave excitation, current effective value 3.5A.

[0037] Table 1: Test results of inductance material performance The Isat value of the product of the material obtained from the comparative example and the comparative example was higher under the same preparation conditions, and the loss was obviously lower, which indicated that the material composition and the product structure design had a very important influence on the Isat value and the loss under large current.

[0038] The specific embodiments are merely illustrative of the present application, and are not a limitation on the present application. Through the above description, relevant personnel can make various changes and modifications without departing from the scope of the technical idea of the present application. The technical scope of the present application is not limited to the content of the specification, and must be determined according to the scope of the claims.

Claims

1. A multiphase coupled inductor material, characterized by: The magnet (1), the first winding (2) and the second winding (3) are included, the first winding (2) forms an up-down electrode structure by leading out in an up-down manner, the second winding (3) is arranged on one side of the first winding (2) and forms a coupling structure with the first winding (2), and the second winding (3) extends out of the magnet (1) to form an electrode; the magnet (1) is composed of mixed powder of iron-based alloy and Cr powder and Al powder, the iron-based alloy contains the following components with mass percentage: 1-3% Si, 25-35% Ni, 1.5-4% Al, 0.5-2% V, and the balance is iron.

2. A multi-phase coupled inductive material according to claim 1, wherein: The gap between the first winding (2) and the second winding (3) is provided with a winding separation layer (4).

3. A polyphase coupled inductive material according to claim 2, wherein: The winding separation layer (4) includes spherical NiZn ferrite powder with a particle size of 0.05-0.15 μm.

4. A polyphase coupled inductive material according to claim 3, wherein: The width of the winding separation layer (4) is 0.1-0.15 μm.

5. A multi-phase coupled inductive material as claimed in claim 1, wherein: The length of the second winding (3) is 50-100% of the length of the first winding (2).

6. A polyphase coupled inductive material according to claim 5, wherein: The electrode formed by the second winding (3) has a gap of 0.2-0.5 mm with the electrode formed by the first winding (2).

7. A polyphase coupled inductive material as claimed in claim 1, wherein: The particle size of the iron-based alloy is 5-15 μm, and the iron-based alloy accounts for 98.5-99.5% of the mass of the mixed powder.

8. A polyphase coupled inductive material according to claim 7, wherein: The surface of the iron-based alloy includes a first layer of cladding and a second layer of cladding, the first layer of cladding includes aluminum oxide, titanium oxide, chromium oxide and iron oxide, and has a thickness of 10-50 nm; the second layer of cladding includes silicon oxide and aluminum oxide, and has a thickness of 5-20 nm.

9. A multiphase coupled inductive material as claimed in claim 1, wherein: The particle size of the Cr powder and Al powder is 0.5-1.0 μm, the surface of the Cr powder and Al powder has an oxide layer formed by itself, and the thickness of the oxide layer is 50-100 nm.

10. A multiphase coupled inductive material as claimed in claim 1, wherein: The surface of the mixed powder of the iron-based alloy, Cr powder and Al powder is treated by a resin treatment agent to obtain a resin cladding layer, the resin treatment agent includes one of epoxy resin, phenolic resin and silicone resin, and the thickness of the resin cladding layer is 100-200 nm.

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