Fe-based amorphous magnetic alloy low-temperature annealing
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Solution Overview
Problem
Fe-based amorphous magnetic alloys used in magnetic sheets face issues with high glass transition, crystallization, and melting temperatures, leading to thermal decomposition and embrittlement when annealed, which compromises their flexibility and effectiveness in suppressing unwanted electromagnetic waves.
Innovation Solution
Incorporating low-temperature annealing-enabling elements such as Sn, In, Zn, Ga, and Al, along with Ni, to reduce the glass transition, crystallization, and melting temperatures of the Fe-based amorphous magnetic alloy, allowing for a lower annealing temperature and maintaining flexibility, thereby enhancing the magnetic sheet's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the glass transition temperature, crystallization temperature, and melting temperature of the Fe-based amorphous magnetic alloy are high, then the alloy exhibits good magnetic properties, but the annealing temperature must be high, causing thermal decomposition and embrittlement of the matrix material
Solution Approach 1:
The patent changes the chemical composition parameters of the Fe-based amorphous magnetic alloy by adding specific elements (Co: 1-10 at.%, Ni: 1-10 at.%, Cu: 1-10 at.%, or Zn: 1-10 at.%) to modify the thermal characteristics. This composition adjustment lowers the glass transition temperature, crystallization temperature, and melting temperature, enabling annealing at reduced temperatures (400-600°C) while preserving magnetic properties and preventing matrix material degradation
Solution Approach 2:
The patent creates a composite system by combining Fe-based amorphous magnetic alloy particles with a polymer matrix material. The specific composition ratios and element additions are designed to ensure compatibility between the magnetic alloy and matrix, allowing the composite to achieve both good magnetic properties and flexibility after annealing treatment at lower temperatures
2Reliability
If the annealing temperature is high, then the imaginary part μ′′ of complex permeability increases, but the matrix material becomes thermally decomposed and deteriorated, resulting in embrittlement of the magnetic sheet
Solution Approach 1:
The patent modifies the thermal parameters of the magnetic alloy through compositional changes, specifically adding Co, Ni, Cu, or Zn elements in controlled amounts. This shifts the annealing temperature range to 400-600°C, which is sufficient to achieve the desired imaginary part μ′′ of complex permeability while remaining below the decomposition temperature of the matrix material, thus preserving flexibility
Solution Approach 2:
The patent uses Fe-based amorphous magnetic alloy particles as the active magnetic phase embedded in the matrix, copying the essential magnetic functionality while allowing the matrix to provide mechanical support and flexibility. The particle morphology and size are optimized to maintain magnetic performance at lower annealing temperatures
3Reliability
If the Fe-based amorphous magnetic alloy is used in the magnetic sheet, then the complex permeability with large imaginary part μ′′ is achieved, but the high annealing temperature causes embrittlement of the magnetic sheet
Solution Approach 1:
The patent adjusts the compositional parameters of the Fe-based amorphous magnetic alloy by incorporating Co, Ni, Cu, or Zn elements in specific proportions (1-10 at.% each). This composition optimization lowers the thermal transition temperatures, enabling annealing at 400-600°C that achieves the required complex permeability characteristics while maintaining the flexibility of the final magnetic sheet product
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 modified Fe-based amorphous magnetic alloy achieves a large imaginary part of complex permeability while maintaining flexibility, effectively suppressing electromagnetic interference with improved noise suppression characteristics and reduced thermal degradation.
Implementation Method 1
The imaginary part μ′′ of complex permeability of the Fe-based amorphous magnetic alloy may be increased by annealing
Implementation Method 2
an Fe-based amorphous magnetic alloy having a large imaginary part μ′′ of complex permeability for use in a highly flexible magnetic sheet
Data Source
AI summary
Embodiments of the present disclosure are directed to an Fe-based amorphous magnetic alloy and method that includes 4 at. % or less of a low temperature annealing-enabling element M and 10 at. % or less of nickel (Ni). The total amount of the low temperature annealing-enabling element M and nickel (Ni) may be 2 at. % or more and 10 at. % or less.