Dust Core Grain Boundary Composition for Higher Magnetic Permeability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing magnetic materials and components face challenges in achieving high initial permeability and saturation magnetization due to limitations in composition and insulation coatings, particularly in dust cores and magnetic components.
Innovation Solution
Incorporating soft magnetic metal particles with a grain boundary phase containing Si and Ti, along with an insulation layer made of Si and Ti oxides, enhances the initial permeability and saturation magnetization by optimizing the composition and structure of the dust core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation coatings are used on soft magnetic metal particles, then manufacturing is simpler, but initial permeability and saturation magnetization are insufficient
Solution Approach 1:
The patent applies composite materials by creating a grain boundary phase containing multiple oxides (silicon oxide, titanium oxide, and optionally aluminum oxide, barium oxide, or boron oxide) rather than using a single insulation coating material. This composite approach enables simultaneous achievement of high initial permeability and saturation magnetization while maintaining adequate insulation properties.
Solution Approach 2:
The patent employs parameter changes by optimizing the compositional ratios of various oxides in the grain boundary phase. Specifically, it controls the content of silicon oxide (0.1-10 wt%), titanium oxide (0.1-10 wt%), and optional additives (0.1-5 wt% each) to achieve the desired magnetic properties. This systematic parameter optimization resolves the contradiction between performance and complexity.
2Reliability
If the grain boundary phase contains multiple oxides, then magnetic properties improve, but manufacturing precision requirements increase
Solution Approach 1:
The patent systematically optimizes the compositional parameters of the grain boundary phase, specifying precise ranges for each oxide component. By controlling silicon oxide at 0.1-10 wt%, titanium oxide at 0.1-10 wt%, and optional additives at 0.1-5 wt% each, the patent achieves high saturation magnetization while providing clear manufacturing guidelines that balance precision requirements with achievable production standards.
Data Source
AI summary
A dust core including soft magnetic metal particles and a grain boundary phase, wherein the grain boundary phase includes Si and Ti.