Coated Fe-Co Soft Magnetic Alloy Powder for Low-Loss Components
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Solution Overview
Problem
Fe—Co alloys, despite having high saturation magnetic flux density, suffer from high loss characteristics, limiting their application in small electronic components.
Innovation Solution
A soft magnetic alloy powder is developed, comprising a core with an amorphous phase Fe—Co alloy or a mixture of amorphous and nanocrystalline phases, coated with a Co oxide layer, achieving an amorphous rate of 95% or more and an average coating thickness of 4 nm to 50 nm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If Fe—Co alloys are used to achieve high saturation magnetic flux density, then the saturation magnetic flux density is improved, but the loss increases
Solution Approach 1:
The patent uses a composite structure consisting of an amorphous phase Fe—Co alloy core combined with a nanocrystalline phase coating layer. This composite material approach allows the core to provide high saturation magnetic flux density while the nanocrystalline coating reduces overall loss, resolving the contradiction between high saturation magnetic flux density and low loss
Solution Approach 2:
The patent changes the structural parameters of the Fe—Co alloy by controlling the amorphous phase content (amorphous rate of 60% or more) and adjusting the Co content (5 atom % to 25 atom %). By optimizing these parameters, the material achieves both high saturation magnetic flux density and reduced loss characteristics
2Quantity of substance
If Co content is increased to improve saturation magnetic flux density, then the saturation magnetic flux density is improved, but the loss increases
Solution Approach 1:
The patent optimizes the Co content parameter within a specific range (5 atom % to 25 atom %) to achieve the desired balance between saturation magnetic flux density and loss. This parameter optimization prevents excessive Co content from causing high loss while maintaining sufficient saturation magnetic flux density
3Loss of energy
If amorphous phase content is increased to reduce loss, then the loss is reduced, but the saturation magnetic flux density may decrease
Solution Approach 1:
The patent creates a composite material system where the amorphous phase Fe—Co alloy core provides high saturation magnetic flux density while the nanocrystalline phase coating contributes to low loss. This composite structure allows both high amorphous phase content (60% or more) and high saturation magnetic flux density to coexist
Solution Approach 2:
The patent applies different material qualities to different parts of the structure: the core region has high amorphous phase content for low loss, while the coating layer has nanocrystalline structure. This local differentiation allows each region to optimize its function without compromising the other
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 soft magnetic alloy powder exhibits excellent loss characteristics and high saturation magnetic flux density, making it suitable for use in small electronic components.
Implementation Method 1
Fe—Co alloys have a high loss compared to Fe-based alloys
Implementation Method 2
high saturation magnetic flux density
Implementation Method 3
Fe—Co alloys have a high loss compared to Fe-based alloys
Implementation Method 4
amorphous phase Fe—Co alloy
Data Source
AI summary
A soft magnetic alloy powder includes a core including an amorphous phase Fe—Co alloy or a Fe—Co alloy in which an amorphous phase and a nanocrystalline phase are mixed and a first coating layer disposed to surround the core and including a Co oxide, wherein Co is included in an amount of 5 atom % to 25 atom % in the entire Fe—Co alloy, and an amorphous rate of the soft magnetic alloy powder is 95% or more.