Fe-Si-Al Powder Magnetic Core Composition for High-Temperature DC Bias
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Solution Overview
Problem
Conventional Fe—Si—Al-based magnetic materials reduce hysteresis loss at room temperature but experience increased hysteresis loss and decreased permeability at high temperatures, particularly when large currents flow, leading to unfavorable DC superimposition characteristics.
Innovation Solution
A magnetic material comprising Fe—Si—Al-based metal magnetic powder with specific composition ratios (7.2% ≤ Si ≤ 8.1% and 6.0% ≤ Al ≤ 7.5% by weight) and manufacturing processes including pressure-molding and heat treatment between 650°C and 800°C to form a powder magnetic core with improved high-temperature performance and DC superimposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional Fe—Si—Al-based magnetic material is used, then hysteresis loss is reduced at room temperature, but hysteresis loss increases in the high-temperature range
Solution Approach 1:
The patent applies parameter changes by precisely controlling the compositional parameters (Si content: 7.0-8.5 wt%, Al content: 6.0-7.5 wt%, and the relationship 2A+B≤22.7) of the Fe-Si-Al-based magnetic powder to achieve optimal magnetic properties across a wide temperature range, resolving the contradiction between room temperature and high temperature hysteresis loss
Solution Approach 2:
The patent uses composite materials by combining Fe-Si-Al-based magnetic powder with specific compositional ratios and conducting heat treatment at 650-800°C to create a composite structure that maintains low hysteresis loss both at room temperature and high temperature, effectively addressing the temperature-dependent performance contradiction
2Loss of energy
If magnetic material for high-temperature performance is used, then magnetic loss is reduced in high-temperature range, but permeability decreases when large current flows
Solution Approach 1:
The patent changes the compositional parameters within optimized ranges (Si: 7.0-8.5 wt%, Al: 6.0-7.5 wt%) and applies controlled heat treatment (650-800°C) to achieve a balance between high-temperature magnetic loss reduction and maintenance of high permeability under DC superimposition conditions
Solution Approach 2:
The patent applies local quality by creating specific microstructural characteristics through controlled heat treatment that provide different properties for different operating conditions: low magnetic loss at high temperature and high permeability under DC current, thus resolving the contradiction between high-temperature performance and DC superimposition characteristics
3Ease of manufacture
If conventional sendust alloy powder is used, then manufacturing process is simple, but DC superimposition characteristics are unfavorable under large current
Solution Approach 1:
The patent modifies the compositional parameters of conventional sendust alloy by precisely controlling Si content (7.0-8.5 wt%) and Al content (6.0-7.5 wt%) and applies heat treatment at 650-800°C to improve DC superimposition characteristics while maintaining ease of manufacture through established pressure-molding and heat treatment processes
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 solution effectively inhibits magnetic loss increase in the high-temperature range and maintains excellent DC superimposition characteristics, ensuring stable inductor performance by optimizing the composition and processing of the Fe—Si—Al-based metal magnetic powder.
Implementation Method 1
A magnetic material including an Fe—Si—Al-based metal magnetic powder
Implementation Method 2
hysteresis loss that is one type of magnetic loss
Data Source
AI summary
A magnetic material includes an Fe—Si—Al-based metal magnetic powder. The Fe—Si—Al-based metal magnetic powder has the following relationships when the Si content is A% by weight and the Al content is B% by weight: 7.2% by weight≤A≤8.1% by weight, 6.0% by weight≤B≤7.5% by weight, and 2A+B≤22.7% by weight.