Fe-B-Si Soft Magnetic Alloy for Wireless Power
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Solution Overview
Problem
Fe-based soft magnetic alloys used in wireless charging systems face challenges with low saturated magnetic flux density and high manufacturing costs at high frequency bands, and existing materials struggle with processing and cost efficiency.
Innovation Solution
A soft magnetic alloy composition of Fe, B, and Si, with specific atomic percentage ranges (84.5-91.0% Fe, 5.3-9.0% B, and 3.8-6.5% Si), providing high saturated magnetic flux density and low AC magnetic loss, suitable for frequency bands of 150 kHz to 250 kHz, and processed through annealing for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Fe-Si soft magnetic alloy is used, then saturated magnetic flux density is improved (1.5 T to 1.9 T), but resistivity is too low for high frequency operation (110 to 250 kHz)
Solution Approach 1:
The patent uses a composite alloy system combining Fe, B, and Si elements. The Fe provides high saturated magnetic flux density, while B and Si work synergistically to increase resistivity for high frequency operation. This composite approach allows simultaneous optimization of magnetic performance and electrical properties that cannot be achieved with simple Fe-Si alloys.
Solution Approach 2:
The patent optimizes specific compositional parameters within defined ranges: Fe (82-90 at%), B (5-15 at%), and Si (3-10 at%). By precisely controlling these parameter ranges, the alloy achieves both high saturated magnetic flux density (>1.8 T) and sufficiently high resistivity for 110-250 kHz operation, resolving the contradiction between magnetic strength and frequency applicability.
2Reliability
If amorphous soft magnetic alloy including Fe and metalloid element is used, then frequency band applicability is improved (110 to 250 kHz), but saturated magnetic flux density decreases (1.56 T or less)
Solution Approach 1:
The patent employs a composite amorphous alloy structure combining Fe with specific ratios of B and Si. This composite composition enables the material to simultaneously achieve high frequency applicability (110-250 kHz) through amorphous structure and high saturated magnetic flux density (>1.8 T) through optimized elemental composition, overcoming the limitation of conventional amorphous alloys.
Solution Approach 2:
The patent defines specific compositional parameter ranges: Fe (82-90 at%), B (5-15 at%), and Si (3-10 at%). These parameter optimizations ensure the alloy maintains amorphous structure for high frequency performance while achieving saturated magnetic flux density exceeding 1.8 T, thus resolving the contradiction between frequency applicability and magnetic strength.
3Strength
If soft magnetic alloy with high saturated magnetic flux density is used, then manufacturing cost increases
Solution Approach 1:
The patent optimizes compositional parameters to use predominantly Fe (82-90 at%), which is abundant and cost-effective, combined with smaller amounts of B (5-15 at%) and Si (3-10 at%). This parameter optimization achieves high saturated magnetic flux density (>1.8 T) while maintaining cost-effectiveness through efficient use of expensive alloying elements, resolving the contradiction between performance and manufacturing cost.
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 saturated magnetic flux density, low AC magnetic loss, and improved processing capabilities, reducing material costs and enabling efficient wireless power transmission and reception in high-frequency wireless charging systems.
Implementation Method 1
the soft magnetic sheet of the wireless power transmitting apparatus, and the soft magnetic sheet of the wireless power receiving apparatus may shield electromagnetic waves radiated from the transmission coil and electromagnetic waves received by the reception coil
Implementation Method 2
processed through annealing for enhanced properties
Data Source
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AI summary
The present invention relates to a soft magnetic alloy and, more specifically, to a soft magnetic alloy used in electric transformers, pulse generators, compressions, electric chokes, energy-accumulating inductors, magnetic sensors, or the like, and a wireless power transmitting apparatus (200 ; 1200) and wireless power receiving apparatus (300 ; 1300) including the soft magnetic alloy.