Bimodal Magnetic Material for Low-Loss Inductors
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Solution Overview
Problem
Conventional magnetic materials face challenges in achieving high magnetic flux density and low loss at high frequencies, making them unsuitable for modern electronic devices that require smaller and lighter supply systems capable of operating at higher frequencies.
Innovation Solution
A magnetic material comprising first magnetic particles (1 μm to 50 μm in size) and second magnetic particles (5 to 50 nm in size) with intermediate phases, which enhance magnetic coupling and insulation properties, resulting in high magnetic permeability and low loss, is developed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional magnetic materials are used, then magnetic flux density can be maintained, but loss increases at high frequencies
Solution Approach 1:
The patent employs a composite material structure consisting of two distinct magnetic particle size ranges (first magnetic particles: 1-50 μm, second magnetic particles: 5-50 nm) combined with intermediate phases. This composite structure allows the material to achieve both high magnetic flux density (from the larger particles) and low loss at high frequencies (from the smaller particles and intermediate phases), resolving the contradiction between maintaining magnetic performance and reducing energy loss.
Solution Approach 2:
The patent applies local quality by creating different regions with distinct functions: larger first magnetic particles provide magnetic flux density in specific regions, while smaller second magnetic particles and intermediate phases are distributed to reduce loss in high-frequency operating regions. This spatial differentiation of material properties allows simultaneous optimization of both magnetic flux density and loss characteristics.
2Volume of moving object
If magnetic material size is reduced for smaller inductor elements, then device size decreases, but magnetic permeability may be compromised
Solution Approach 1:
The composite material with bimodal particle size distribution enables miniaturization of inductor elements while maintaining magnetic permeability. The combination of larger first magnetic particles (maintaining flux density) and smaller second magnetic particles (improving high-frequency response and packing density) allows compact inductor design without sacrificing magnetic performance.
Solution Approach 2:
The patent implements a nested structure where smaller second magnetic particles are positioned within the interstices between larger first magnetic particles. This nesting approach maximizes space utilization, allowing smaller inductor elements to achieve the required magnetic permeability through efficient spatial arrangement of particles across different size scales.
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 magnetic material achieves high real part of magnetic permeability and low imaginary part at high frequencies, enabling the creation of smaller and lighter inductor elements with improved high-frequency performance.
Implementation Method 1
first magnetic particles that contain at least one magnetic metal selected from the group including Fe, Co, and Ni, are 1 μm or greater in particle size, and are 5 to 50 μm in average particle size; second magnetic particles that contain at least one magnetic metal selected from the group including Fe, Co, and Ni, are smaller than 1 μm in particle size, and are 5 to 50 nm in average particle size; and intermediate phases that exist between the first magnetic particles and the second magnetic particles
Data Source
AI summary
A magnetic material of an embodiment includes: first magnetic particles that contain at least one magnetic metal selected from the group including Fe, Co, and Ni, are 1 μm or greater in particle size, and are 5 to 50 μm in average particle size; second magnetic particles that contain at least one magnetic metal selected from the group including Fe, Co, and Ni, are smaller than 1 μm in particle size, and are 5 to 50 nm in average particle size; and an intermediate phase that exists between the first magnetic particles and the second magnetic particles.