Laminated Magnetic Cores With Partially Conductive Interlayers
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Solution Overview
Problem
Conventional laminated magnetic cores face challenges in suppressing eddy current losses at high operating frequencies due to the use of insulating interlamination layers, leading to fabrication complexity and limited high-frequency performance.
Innovation Solution
The development of laminated magnetic cores with interlamination layers having balanced electrical conductivities, ranging between 10−4 S/cm and 10⁵ S/cm, allows for simplified fabrication through sequential electrodeposition while effectively suppressing eddy current losses, using partially conducting materials like conductive polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional insulating interlamination layers are used, then eddy current losses are suppressed, but fabrication complexity increases
Solution Approach 1:
The patent changes the electrical conductivity parameter of the interlamination layer from insulating (conventional) to partially conducting (10^-4 to 10^5 S/cm), achieving a balance that suppresses eddy current losses while enabling simplified electrodeposition fabrication
Solution Approach 2:
The patent introduces partially conducting interlamination layers as an intermediary between magnetic layers, which serve dual functions: suppressing eddy currents and enabling electrodeposition, thereby resolving the contradiction between energy loss suppression and fabrication simplicity
2Loss of energy
If insulating interlamination layers are used, then eddy current losses are suppressed, but high-frequency performance is limited
Solution Approach 1:
The patent optimizes the electrical conductivity parameter of interlamination layers to a specific range (10^-4 to 10^5 S/cm), which maintains eddy current suppression while improving high-frequency performance through better electrodeposition quality and magnetic layer formation
3Ease of manufacture
If conventional fabrication methods are used, then insulating layers are deposited, but fabrication complexity increases
Solution Approach 1:
The partially conducting interlamination layer acts as an intermediary that enables electrodeposition, simplifying the fabrication process by allowing direct metal deposition without complex insulation handling
Solution Approach 2:
By changing the conductivity parameter of the interlamination layer to a partially conducting state, the patent enables electrodeposition fabrication, transforming a complex insulation-deposition process into a simpler electrochemical deposition process
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 laminated magnetic cores achieve uncompromised high-frequency performance with reduced fabrication complexity, enabling the production of miniaturized inductive components and devices with higher saturation flux densities, suitable for applications like DC-DC converters and handheld devices.
Implementation Method 1
the eddy current losses within the volume of the laminated alloys can be suppressed even at MHz frequencies
Implementation Method 2
the conductivities of the interlamination layers are sufficiently high to enable subsequent electrodeposition of metal (e.g., the next lamination layer)
Data Source
AI summary
The subject matter described herein relates to laminated magnetic cores, methods of fabricating laminated magnetic cores, and electric devices using laminated magnetic cores. In some examples, a method for fabricating a laminated magnetic core includes depositing a first magnetic layer and depositing an interlamination layer of over the first magnetic layer. The interlamination layer comprises a partially conducting material having a conductivity greater than or equal to 10−4 S/cm and less than or equal to 105 S/cm. The method includes depositing a second magnetic layer over the interlamination layer. The method can include sequentially depositing additional interlamination layers and additional magnetic layers in an alternating fashion to produce the laminated magnetic core.