Fe-Based Nanocrystalline Alloy for Wireless Power Transmission
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Solution Overview
Problem
Existing Fe-based nanocrystalline alloys with high saturation magnetic flux density suffer from high losses and heat generation, limiting their efficiency in applications like wireless power transmission and magnetic induction devices.
Innovation Solution
An Fe-based nanocrystalline alloy composition (Fe(1-a)M1a)100-b-c-d-e-gM2bBcPdCueM3g) with specific elemental ratios and a bimodal DSC graph, where M1 includes Co and Ni, M2 includes Nb, Mo, Zr, etc., and M3 includes C, Si, Al, and Ge, is developed, allowing for low loss and high saturation magnetic flux density, and is used in electronic components with magnetic particles dispersed in an insulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a magnetic material with high saturation magnetic flux density is used to improve wireless power transmission efficiency, then the transmission efficiency is improved, but the material generates high losses and heat
Solution Approach 1:
The patent changes the chemical composition parameters of the Fe-based alloy by adding specific elements (Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, Mn) in controlled amounts to achieve a saturation magnetic flux density of 1.4 T or more while maintaining core loss below 0.6 W/kg at 6.78 MHz, resolving the contradiction between high power efficiency and low energy loss
Solution Approach 2:
The patent creates a composite Fe-based nanocrystalline alloy combining multiple elements (Fe, Co, Ni, Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, Mn, B, Cu, Si, Al, Ga, Ge, P) to achieve both high saturation magnetic flux density and low core loss, transforming a single-material limitation into a multi-element solution
2Strength
If the saturation magnetic flux density is increased to improve device performance, then the magnetic induction capability is enhanced, but heat generation increases
Solution Approach 1:
The patent adjusts compositional parameters to achieve Bs≥1.4 T while controlling heat generation through optimized element ratios, particularly utilizing Nb (2-3 at%) and B (9-11 at%) to enhance magnetic properties without proportional increase in heat
3Strength
If existing Fe-based nanocrystalline alloy compositions are used to achieve high saturation magnetic flux density, then the magnetic properties are improved, but the core loss increases
Solution Approach 1:
The patent systematically changes compositional parameters from existing alloys by adding specific amounts of Nb (2-3 at%), B (9-11 at%), Cu (0.6-1.5 at%), and other elements to achieve the optimal balance of Bs≥1.4 T and core loss<0.6 W/kg at 6.78 MHz
Solution Approach 2:
The patent develops a multi-element composite Fe-based alloy combining ferromagnetic elements (Fe, Co, Ni) with microalloying elements (Nb, B, Cu, Si, Al, Ga, Ge) and trace elements (Ta, W, Hf, Ti, V, Cr, Mn) to simultaneously achieve high saturation magnetic flux density and low core loss
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 a high saturation magnetic flux density of 1.4 T or more with reduced core losses, enabling efficient wireless power transmission and improved device performance by controlling nanocrystalline grain size and phase structure through heat treatment.
Implementation Method 1
In magnetic induction type wireless power transmission equipment, a magnetic material is used to decrease an influence of electromagnetic interference (EMI)/electromagnetic compatibility (EMC) caused by a surrounding metal material and improve wireless power transmission efficiency
Implementation Method 2
In a differential scanning calorimetry (DSC) graph, a primary peak may have a bimodal shape
Implementation Method 3
heat treating the parent phase of the Fe-based nanocrystalline alloy to obtain the Fe-based nanocrystalline alloy
Data Source
AI summary
An Fe-based nanocrystalline alloy is represented by Composition Formula, (Fe(1-a)M1a)100-b-c-d-e-gM2bBcPdCueM3g, where M1 is at least one element selected from Co and Ni, M2 is at least one element selected from the group consisting of Nb, Mo, Zr, Ta, W, Hf, Ti, V, Cr, and Mn, M3 is at least one element selected from the group consisting of C, Si, Al, Ga, and Ge, and 0≤a≤0.5, 2≤b≤3, 9≤c≤11, 1≤d≤2, 0.6≤e≤1.5, and 9≤g≤11.