Magnetic Core Particle Spacing for Low Core Loss Under DC Bias
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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.
Innovation Solution
A magnetic core is designed with soft magnetic particles, where the median distance (M) between large particles is within the range of 1.0 μm to (0.5×D50), and the volume-based particle size distribution is optimized to enhance DC superimposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If amorphous alloy powder is used as metal magnetic powder, then core loss is reduced, but density of the dust core becomes difficult to increase during molding
Solution Approach 1:
The patent applies parameter changes by controlling the particle size distribution of amorphous alloy powder within specific ranges (D10-D90: 0.5-5.0 μm, D50: 1.0-3.0 μm) and adjusting the average working sphericity to 0.85 or higher. These parameter optimizations enable both reduced core loss and improved molding density, resolving the technical contradiction between energy loss reduction and manufacturing precision.
2Ease of manufacture
If conventional metal magnetic powder is used, then manufacturing is easier, but core loss is readily increased
Solution Approach 1:
The patent changes the physical parameters of the magnetic powder by specifying amorphous alloy powder with controlled particle size (D10-D90: 0.5-5.0 μm, D50: 1.0-3.0 μm) and high average working sphericity (0.85 or more). These parameter modifications maintain ease of molding while significantly reducing core loss compared to conventional metal magnetic powders.
3Reliability
If particle size of soft magnetic particles is increased, then DC superimposition characteristics improve, but core loss may increase
Solution Approach 1:
The patent optimizes particle size parameters by controlling D10-D90 to 0.5-5.0 μm and D50 to 1.0-3.0 μm, achieving a balance where DC superimposition characteristics are improved through adequate particle size while core loss is minimized through the amorphous structure and controlled size distribution.
Solution Approach 2:
The patent uses amorphous alloy powder with specific compositional elements (Fe, Co, Ni, B, Si, Cr, Mn, Al, Ga, Ag, Zn, S, Ca, Mg, V, Sn, As, Sb, Bi, N, Au, Cu, and rare earth elements) to create a composite material structure that simultaneously achieves good DC superimposition characteristics and low core loss.
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 optimized magnetic core exhibits improved DC superimposition characteristics and reduced core loss, maintaining high permeability while enhancing magnetic performance.
Implementation Method 1
a magnetic core including soft magnetic particles
Data Source
AI summary
A magnetic core includes soft magnetic particles. Large particles denote soft magnetic particles having a particle size of (0.5×D50) or more in a volume-based particle size distribution of the soft magnetic particles. M is within a specific range, where M denotes a median of AL of the large particles, and AL denotes an average distance from one of the large particles to three of the large particles nearest to the one of the large particles.