Magnetic Core Particle Circularity for Withstand Voltage
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Solution Overview
Problem
Existing magnetic cores face challenges in achieving high relative magnetic permeability while maintaining a high withstand voltage property, as improving magnetic material density often leads to decreased withstand voltage due to increased electric field concentration.
Innovation Solution
A magnetic core composition featuring large and small soft magnetic particles with specific size and circularity ratios, where the small particles close to the large particles have a lower average circularity than those further away, along with a resin or voids occupying non-magnetic material areas, enhances both relative magnetic permeability and withstand voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If small particles with high circularity are used to improve packing density, then the density of the magnetic core is improved, but the withstand voltage property deteriorates due to increased electric field concentration at particle contact points
Solution Approach 1:
The patent applies parameter changes by systematically varying the circularity parameter of small particles based on their spatial relationship to large particles. Small particles adjacent to large particles are given lower circularity (C1 < C2) to reduce electric field concentration, while other small particles maintain higher circularity for density. This conditional parameter adjustment resolves the contradiction between density and withstand voltage by making particle shape a function of position rather than a uniform property.
Solution Approach 2:
The patent implements local quality by differentiating particle characteristics based on location: small particles in high-electric-field regions (near large particles) have reduced circularity to mitigate field concentration, while small particles in other regions maintain higher circularity. This localized adaptation of particle properties allows the system to achieve both high density and high withstand voltage property by addressing the specific requirements of different spatial zones.
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
This approach improves the magnetic core's withstand voltage property while maintaining high relative magnetic permeability by optimizing particle size and shape distribution and material density, reducing electric field concentration points.
Implementation Method 1
a magnetic core according to the present invention contains: large particles observed as soft magnetic particles having a Heywood diameter of 5 μm or more and 25 μm or less and small particles observed as soft magnetic particles having a Heywood diameter of 0.5 μm or more and less than 5 μm in a cross section
Data Source
AI summary
To obtain a magnetic core having an improved withstand voltage property while maintaining a high relative magnetic permeability, and the like. The magnetic core contains large particles observed as soft magnetic particles having a Heywood diameter of 5 μm or more and 25 μm or less and small particles observed as soft magnetic particles having a Heywood diameter of 0.5 μm or more and less than 5 μm in a cross section. C1<C2 is satisfied in which an average circularity of the small particles close to the large particles is C1 and an average circularity of all small particles observed in the cross section including small particles not close to the large particles is C2. The small particles close to the large particles are defined as small particles whose distance from centroids of the small particles to a surface of the large particles is 3 μm or less.