Amorphous Soft Magnetic Powder for Low Core Loss at High Frequency
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Solution Overview
Problem
Existing soft magnetic powders, such as iron-based metal glass alloy powders, do not adequately address the reduction of coercive force while maintaining satisfactory magnetic properties, particularly in high frequency applications, where core loss is a significant concern.
Innovation Solution
The development of an amorphous metal particle composition expressed by the formula Fe100-a-b-c-d-e-f-gCraSibBCCdAleTifCog, where specific atomic percentages are optimized to reduce coercive force and enhance magnetic permeability, allowing for heat treatment that suppresses crystallization and anisotropy, thereby achieving low coercive force and high magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If iron-based metal glass alloy powder is used to improve magnetic property through amorphous single phase, then magnetic permeability is improved, but coercive force cannot be sufficiently reduced for low core loss
Solution Approach 1:
The patent applies parameter changes by precisely controlling the compositional parameters of the amorphous alloy, specifically setting Fe content to 65-75 atom%, Si to 5-15 atom%, and B to 7-15 atom%, while limiting other elements to specific ranges. This compositional parameter optimization enables the material to achieve both high magnetic permeability and low coercive force, resolving the contradiction between these two magnetic properties.
Solution Approach 2:
The patent creates a composite amorphous alloy system combining Fe, Si, B, and trace elements (Al, Ti, Co, Cr, Mn, Mo) in specific proportions. This composite material approach leverages the synergistic effects of different elements: Fe provides magnetic properties, Si and B suppress crystallization and reduce anisotropy, while trace elements further optimize magnetic characteristics, achieving both high permeability and low coercive force simultaneously.
2Volume of moving object
If compact size is reduced for miniaturization, then device size is reduced, but core loss increases due to high frequency effects
Solution Approach 1:
The patent utilizes parameter changes by optimizing the compositional parameters to achieve low coercive force (0.5-5.0 Oe), which directly reduces hysteresis loss. Additionally, the high specific resistance achieved through the amorphous structure (controlled by Si and B content) suppresses eddy current loss. These parameter optimizations enable compact designs with reduced size while maintaining low core loss at high frequencies.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This composition results in soft magnetic powders with significantly reduced coercive force and improved magnetic permeability, leading to compact designs with reduced size and increased efficiency, effectively minimizing hysteresis and eddy current losses in high frequency regions.
Implementation Method 1
allowing for heat treatment that suppresses crystallization and anisotropy
Implementation Method 2
heat treatment that suppresses crystallization and anisotropy
Implementation Method 3
it is required to reduce a coercive force of the soft magnetic powder... effectively minimizing hysteresis and eddy current losses
Implementation Method 4
effectively minimizing hysteresis and eddy current losses in high frequency regions
Data Source
AI summary
Provided is soft magnetic powder containing an amorphous metal particle having a composition expressed by a compositional formula Fe100-a-b-c-d-e-f-gCraSibBcCdAleTifCog. Here, a, b, c, d, e, f, and g are that express atom %, 0<a≤3.0, 5.0≤b≤15.0, 7.0≤c≤15.0, 0.1≤d≤3.0, 0<e≤0.016, 0<f≤0.009, and 0≤g≤0.025.