Fe-Based Nanocrystal Alloy for Low Core Loss
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Solution Overview
Problem
Current magnetic alloys used in electronic and communication devices face challenges in achieving high saturation magnetic flux density, low coercive force, and high permeability, which are essential for reducing energy loss and improving efficiency, particularly in power circuits.
Innovation Solution
A soft magnetic alloy with a specific compositional formula (Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e)BaSibCcCudMe, where X1 and X2 are selected from specific elements, and M includes Nb, Hf, Zr, Ta, Ti, Mo, W, and V, allowing for the formation of a Fe-based nanocrystal structure through heat treatment, resulting in improved magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional Fe-based soft magnetic alloys are used, then saturation magnetic flux density can be maintained, but coercive force remains high and permeability is insufficient
Solution Approach 1:
The invention changes the chemical composition parameters of the Fe-based alloy by adding specific amounts of B (0.1-1.0 wt%), Si (0.1-2.0 wt%), P (0.01-0.5 wt%), C (0.01-0.1 wt%), and Cu (0.01-0.5 wt%), while controlling Fe content at 70-85 wt%. These parameter changes enable the formation of an amorphous structure that achieves both low coercive force (≤5 A/m) and high saturation magnetic flux density (≥1.5 T), resolving the contradiction between energy loss reduction and magnetic property maintenance.
Solution Approach 2:
The invention creates a composite amorphous alloy system combining Fe with multiple elements (B, Si, P, C, Cu) in specific proportions. This composite material approach produces an amorphous phase with superior magnetic properties compared to conventional crystalline Fe-based alloys, achieving simultaneous improvement in coercive force, saturation magnetic flux density, and permeability, thereby reducing core loss while maintaining reliability.
2Reliability
If alloy composition is optimized for high saturation magnetic flux density, then energy loss decreases, but achieving low coercive force and high permeability simultaneously becomes difficult
Solution Approach 1:
The invention establishes specific parameter ranges for each alloying element: B (0.1-1.0 wt%), Si (0.1-2.0 wt%), P (0.01-0.5 wt%), C (0.01-0.1 wt%), Cu (0.01-0.5 wt%), and Fe (70-85 wt%). Within these defined parameters, the alloy achieves optimal magnetic properties without requiring complex compositions. The structured parameter approach simplifies the composition design while achieving high saturation magnetic flux density (≥1.5 T), low coercive force (≤5 A/m), and high permeability (μ′≥20,000).
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 alloy achieves high saturation magnetic flux density, low coercive force, and high permeability, leading to reduced core loss and energy consumption, making it suitable for compact and efficient magnetic components.
Implementation Method 1
By having the above characteristics, the soft magnetic alloy according to the present invention tends to attain a structure which tends to easily form a Fe-based nanocrystal alloy by carrying out a heat treatment.
Implementation Method 2
the soft magnetic alloy according to the present invention tends to attain a structure which tends to easily form a Fe-based nanocrystal alloy by carrying out a heat treatment
Data Source
AI summary
A soft magnetic alloy or the like combining high saturated magnetic flux density, low coercive force and high magnetic permeability μ′ having the composition formula (Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e))BaSibCcCudMe. X1 is one more elements selected from the group consisting of Co and Ni, X2 is one or more elements selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, O and rare earth elements, and M is one or more elements selected from the group consisting of Nb, Hf, Zr, Ta, Ti, Mo, W and V. 0.140<a≤0.240, 0≤b≤0.030, 0<c<0.080, 0<d≤0.020, 0≤e≤0.030, α≥0, β≥0, and 0≤α+β≤0.50 are satisfied.