Magnetic Core Particle Distribution for Low Core Loss
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Solution Overview
Problem
Existing magnetic cores face challenges in achieving improved DC superimposition characteristics and reduced core loss, particularly when using metal magnetic powders which tend to increase core loss.
Innovation Solution
A magnetic core comprising soft magnetic particles with a specific size distribution, where large particles have a size of (0.5×V50) or more and small particles have a size of (2×N50) or less, and the distance L from small to large particles satisfies the condition (2×N50)≤L50≤(0.5×V10+3).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If metal magnetic powder is used for dust core, then core loss is readily increased, but if amorphous alloy powder is used, then core loss is reduced but density of dust core becomes difficult to increase
Solution Approach 1:
The patent uses a composite structure combining amorphous alloy particles (for low core loss) with crystalline alloy particles (for high density and magnetic properties). This composite approach allows the dust core to achieve both reduced core loss and increased density by leveraging the complementary strengths of different material types.
Solution Approach 2:
The patent creates local quality variations by distributing different particle sizes and types throughout the dust core. Small particles fill gaps between large particles to increase density, while specific particle compositions are positioned to optimize magnetic flux paths and reduce core loss in critical regions.
2Loss of energy
If conventional particle size distribution is used, then manufacturing is simplified, but DC superimposition characteristics and core loss performance are insufficient
Solution Approach 1:
The patent applies specific parameter changes to particle size distribution, defining precise relationships between D10, D50, and D90 values. By controlling the ratio of small to large particles and their size distribution parameters, the invention optimizes both DC superimposition characteristics and core loss performance while providing manufacturable specifications.
3Loss of energy
If particle density is increased, then core loss is reduced, but DC superimposition characteristics deteriorate
Solution Approach 1:
The patent creates local quality variations by distributing different particle sizes and types throughout the dust core. Small particles fill gaps between large particles to increase density, while specific particle compositions are positioned to optimize magnetic flux paths and reduce core loss in critical regions.
Solution Approach 2:
The patent uses a composite structure combining amorphous alloy particles (for low core loss) with crystalline alloy particles (for high density and magnetic properties). This composite approach allows the dust core to achieve both reduced core loss and increased density by leveraging the complementary strengths of different material types.
Data Source
AI summary
A magnetic core includes soft magnetic particles. The soft magnetic particles include large particles having a particle size of (0.5×V50) or more and small particles having a particle size of (2×N50) or less, where V10 denotes D10 of a volume-based particle size distribution of the soft magnetic particles, V50 denotes D50 of the volume-based particle size distribution of the soft magnetic particles, and N50 denotes D50 of a number-based particle size distribution of the soft magnetic particles. L50 is within a specific range, where L50 denotes a median of L of the small particles, and L denotes a distance from one of the small particles to one of the large particles nearest to the one of the small particles.