Amorphous Soft Magnetic Powder for High-Frequency Eddy Current Reduction
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Solution Overview
Problem
Magnetic cores in high-frequency applications, such as mobile devices, face increased iron loss due to eddy currents and magnetostriction, which hinders the reduction of size and enhancement of capabilities.
Innovation Solution
A soft magnetic powder with an amorphous alloy composition of Fe100-a-b-c-dMnaSibBcCd, where a, b, c, and d represent atomic percentages within specific ranges, is used to reduce magnetostriction, coercive force, and eddy current loss, while maintaining high saturation magnetic flux density and magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If Fe-based amorphous alloy is used as soft magnetic material, then saturation magnetic flux density is increased, but magnetostriction increases causing heat generation and preventing enhancement of magnetic characteristics
Solution Approach 1:
The patent uses a composite amorphous alloy material containing Fe, Mn, Si, B, and C elements. The specific composition (Fe100-a-b-c-dMnaSibBcCd where 0.1≦a≦10, 3≦b≦15, 3≦c≦15, and 0.1≦d≦3) creates a multi-element composite structure that combines the high saturation magnetic flux density of Fe-based alloys with reduced magnetostriction through the synergistic effects of Mn, Si, B, and C additions.
Solution Approach 2:
The patent changes the chemical composition parameters of the amorphous alloy by specifying precise atomic percentage ranges for each element (Fe, Mn, Si, B, C). This parameter optimization allows the material to achieve both high saturation magnetic flux density and reduced magnetostriction, resolving the contradiction between these two properties.
2Productivity
If driving frequency of magnetic device is increased, then capabilities of mobile devices are enhanced, but Joule loss due to eddy current increases
Solution Approach 1:
The patent changes the electrical resistivity parameter of the soft magnetic material by optimizing the amorphous alloy composition. The specific element ratios (particularly Si and B content) increase the bulk resistivity of the material, which directly reduces eddy current losses and allows high-frequency operation with minimal Joule heating.
Solution Approach 2:
The multi-element amorphous alloy composite structure inherently provides higher resistivity compared to pure Fe-based alloys. The disordered atomic structure and specific element combinations create electron scattering centers that increase resistivity, thereby suppressing eddy currents and enabling high-frequency operation.
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
The soft magnetic powder effectively reduces iron loss and enhances magnetic characteristics, allowing for smaller, high-capability magnetic devices with reduced heat generation and improved frequency responsiveness.
Implementation Method 1
the Fe-based amorphous alloy has a large magnetostriction and thus has a problem that it generates heat at a particular frequency
Implementation Method 2
the magnetic core necessarily suffers considerable increase of Joule loss (eddy current loss) due to the eddy current as the driving frequency of the magnetic device is further increased
Implementation Method 3
considerable increase of Joule loss (eddy current loss)
Data Source
AI summary
A soft magnetic powder containing an amorphous alloy material having an alloy composition represented by Fe100-a-b-c-dMnaSibBcCd wherein a, b, c and d each represent a proportion in terms of percent by atom, and satisfy 0.1≦a≦10, 3≦b≦15, 3≦c≦15, and 0.1≦d≦3.