Soft Magnetic Alloy Powder Circularity Control for Low Core Loss
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Solution Overview
Problem
Existing soft magnetic alloy powders struggle to produce magnetic cores with improved core loss and DC superimposition characteristics due to limitations in particle size and circularity, leading to reduced performance in magnetic components.
Innovation Solution
A soft magnetic alloy powder with a specific compositional formula ((Fe(1−(α+β))CoαNiβ)(1−γ)X1γ)(1−(a+b+c+d+e))BaPbSicCdCre, where X1 includes elements like Ti, Zr, and rare earth elements, is used, and an elliptical water flow atomizing apparatus is employed to produce particles with enhanced average circularity and reduced variance, resulting in improved magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional soft magnetic alloy powders are used, then manufacturing is simpler, but core loss increases and DC superimposition characteristics deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling particle size distribution (D90-based classification) and circularity parameters (average circularity ≥0.75, variance ≤0.035) to reduce core loss while improving DC superimposition characteristics. This resolves the contradiction by establishing specific quantitative parameters that simultaneously achieve energy efficiency and manufacturing precision.
Solution Approach 2:
The patent uses composite material composition with specific alloying elements (Fe, Co, Ni, B, Si, C, Cr, and optional rare earth elements) to achieve both reduced core loss and improved particle characteristics. The composite alloy structure enables simultaneous optimization of magnetic properties and particle morphology, resolving the contradiction between energy loss and manufacturing precision.
2Reliability
If particle size and circularity are not controlled, then manufacturing is easier, but magnetic component performance deteriorates
Solution Approach 1:
The patent establishes specific parameter ranges for particle size (using D90 as reference) and circularity (average ≥0.75, variance ≤0.035) to ensure both manufacturing feasibility and component reliability. These parameter specifications resolve the contradiction by defining a controlled manufacturing window that achieves high performance without excessive complexity.
Solution Approach 2:
The patent implements feedback control through strict specification of particle characteristics (size distribution relative to D90, circularity metrics) that can be measured and controlled during manufacturing. This feedback mechanism ensures consistent magnetic component performance while maintaining manufacturability, resolving the contradiction between reliability and manufacturing precision.
3Reliability
If alloy composition is simplified, then manufacturing is easier, but magnetic properties deteriorate
Solution Approach 1:
The patent employs a composite alloy system with multiple elements (Fe, Co, Ni, B, Si, C, Cr) in specific proportions to achieve superior magnetic properties. The complex composition is justified by the significant improvement in magnetic performance, resolving the contradiction between property reliability and compositional complexity through synergistic element interactions.
Solution Approach 2:
The patent applies local quality by strategically positioning specific alloying elements (e.g., B and Si for amorphous structure formation, rare earth elements for enhanced magnetic properties) within the alloy system. This targeted element placement optimizes magnetic properties without uniformly increasing complexity throughout the entire material system.
Data Source
AI summary
A soft magnetic alloy powder comprises a component having a compositional formula ((Fe(1−(α+β))CoαNiβ)(1−γ)X1γ)(1−(a+b+c+d+e))BaPbSicCdCre in atomic ratio. X1 comprises at least one selected from specific elements. Values of a, b, c, d, e, α, β, and γ of the compositional formula satisfy specific ranges. The soft magnetic alloy powder comprises soft magnetic alloy particles including soft magnetic alloy particles having a particle size of (0.95×D90) or more and (1.05×D90) or less. An average Wadell's circularity of the soft magnetic alloy particles having the particle size of (0.95×D90) or more and (1.05×D90) or less is 0.75 or more. A variance of Wadell's circularity of the soft magnetic alloy particles having the particle size of (0.95×D90) or more and (1.05×D90) or less is 0.035 or less.