Fe-Si-B Magnetic Core Composition for Low-Loss High-Current Coils
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Solution Overview
Problem
Existing magnetic cores in high-current inductors and reactors face challenges in achieving high DC current superposition characteristics with low core loss and high permeability, particularly due to suboptimal density and particle distribution.
Innovation Solution
A magnetic core composed of iron (Fe)-silicon (Si)-boron (B) with varying mass percentages and porosities between its surfaces, along with a resin filling, to optimize density and permeability, resulting in a toroidal shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mass percentage of Fe is uniformly distributed in the magnetic core, then the manufacturing process is simple, but the permeability and loss characteristics cannot be optimized
Solution Approach 1:
The patent applies local quality by creating different Fe mass percentages in different regions of the magnetic core. Specifically, the first surface (upper surface) has a different Fe mass percentage compared to the second surface (side surface), with the ratio of Fe mass percentage in the first surface to the difference between the first and second surfaces being controlled within 6-21. This non-uniform distribution optimizes permeability and reduces core loss by addressing local magnetic field characteristics in different regions of the core.
2Loss of energy
If the density and particle distribution are not optimized, then the manufacturing process is easier, but the core loss increases and permeability decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the Fe mass percentage distribution and its ratio relationship between different surfaces. By maintaining the ratio of Fe mass percentage in the first surface to the difference between first and second surfaces within 6-21, the invention optimizes the magnetic properties to achieve low core loss and high permeability. This parameter control extends to resin content distribution, where the resin mass percentage in the first surface is controlled to be 5-20 times that in the second surface.
3Reliability
If the magnetic core requires high permeability and low loss, then the coil component performance is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent implements local quality through spatially varying material composition, specifically controlling Fe mass percentage and resin mass percentage at different locations within the magnetic core. The first surface region has higher Fe content and resin content compared to the second surface, creating localized property optimization that enhances overall coil component reliability while providing clear manufacturing targets for quality control.
Data Source
AI summary
A magnetic core according to one embodiment of the present invention includes a material formed of iron (Fe)-silicon (Si)-boron (B), wherein a mass percentage of Fe in a first surface, which is an upper surface, is different from a mass percentage of Fe in a second surface which is a side surface, and a ratio of the mass percentage of Fe in the first surface to a difference between the mass percentage of Fe in the first surface and the mass percentage of Fe in the second surface is in the range of 6 to 21.