Magnetic Material Flat Particles Eddy Current Losses
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Solution Overview
Problem
Current magnetic materials face challenges in achieving high magnetic permeability and low magnetic losses in the kHz to MHz frequency range, which is essential for applications like power inductors and radio wave absorbers, as they often suffer from high eddy current losses and reduced mechanical strength due to high aspect ratios.
Innovation Solution
A magnetic material comprising flat particles with a high aspect ratio (10 or higher) and a matrix phase with higher electrical resistance, where the flat particles are laminated with a proportion of 10% or more of the cross-section, effectively suppressing eddy current losses and enhancing saturation magnetization and magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If flat particles with high aspect ratio are used to increase saturation magnetization and magnetic permeability, then magnetic performance is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent uses a composite structure consisting of flat magnetic particles embedded in a binder resin matrix. This composite approach allows the magnetic particles to provide high saturation magnetization and magnetic permeability while the binder resin provides mechanical strength and structural integrity, resolving the contradiction between magnetic performance and mechanical strength
Solution Approach 2:
The patent applies local quality by creating a heterogeneous structure where flat particles are distributed within the binder resin. The flat particles concentrate magnetic properties in specific regions while the binder resin provides structural support throughout the matrix, allowing simultaneous optimization of magnetic performance and mechanical strength
2Loss of energy
If conventional magnetic materials are used in kHz to MHz range, then saturation magnetization is achieved, but eddy current losses increase
Solution Approach 1:
The patent segments the magnetic material into discrete flat particles rather than using bulk magnetic material. This segmentation interrupts eddy current paths, significantly reducing eddy current losses in the kHz to MHz frequency range while maintaining high magnetic permeability through the distributed particle structure
Solution Approach 2:
The patent changes the physical parameters of the magnetic material by using flat particles with specific aspect ratios and controlling their distribution in the binder resin. This parameter optimization allows achieving low eddy current losses while maintaining high saturation magnetization and magnetic permeability in the target frequency range
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 magnetic material achieves high magnetic permeability and low magnetic losses in the high frequency range of 100 kHz or more, while maintaining mechanical strength, making it suitable for power inductors and radio wave absorbers.
Implementation Method 1
the matrix phase disposed around the plurality of flat particles and having higher electrical resistance than the flat particles
Implementation Method 2
a magnetic material exhibits high magnetic losses near the ferromagnetic resonance frequency
Implementation Method 3
a radio wave absorber absorbs the noises generated from electronic instrument by utilizing high magnetic losses
Data Source
AI summary
Provided is a magnetic material including a plurality of flat particles containing a magnetic metal, and a matrix phase disposed around the flat particles and having higher electrical resistance than the flat particles. In a cross-section of the magnetic material, the aspect ratio of the flat particles is 10 or higher. If the major axis of one of the flat particles is designated as L and the length of a straight line connecting two endpoints of the flat particle is designated as W, the proportion of the area surrounded by the outer peripheries of parts in which flat particles satisfying the relationship: W ≤0.95×L are continuously laminated, is 10% or more of the cross-section.