Multi-Phase Magnetic Particle Structure for Packing Density and Loss Control
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Solution Overview
Problem
Magnetic components face challenges in miniaturization due to limitations in increasing packing density and reducing losses, while maintaining magnetic properties, as high pressure can lead to deformation and deteriorated magnetic properties.
Innovation Solution
A magnetic particle with multiple phases, including an Fe-based phase and an Fe3O4 phase, where the Fe3O4 phase occupies less than 50% of the area, and an oxide film is used to minimize loss and optimize coercive force, improving efficiency and magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the body is formed with high pressure to increase packing density of magnetic particles, then packing density is improved, but the magnetic component deforms and magnetic properties deteriorate
Solution Approach 1:
The patent changes the physical and chemical parameters of magnetic particles by creating a multi-phase structure with amorphous phase, Fe-based phase, and Fe3O4 phase. This phase composition modification allows particles to achieve better packing density without requiring excessive compression pressure, thus preventing deformation while improving packing efficiency.
Solution Approach 2:
The patent employs composite magnetic particles consisting of multiple phases (amorphous phase, Fe-based phase, and Fe3O4 phase) with specific area ratios. This composite structure optimizes both packing density and magnetic properties, allowing high packing density to be achieved without the need for high-pressure formation that would cause deformation.
2Loss of energy
If magnetic particles are refined and packing density is increased to reduce loss, then efficiency characteristic is improved, but the size of the body must be increased which conflicts with miniaturization trend
Solution Approach 1:
The patent modifies the physical parameters of magnetic particles through phase composition control (amorphous phase, Fe-based phase, Fe3O4 phase with specific area ratios). This parameter optimization reduces energy loss at the particle level, allowing smaller component sizes to achieve the same efficiency performance that would otherwise require larger volumes.
Solution Approach 2:
The patent applies local quality optimization by controlling the phase distribution and area ratios within individual magnetic particles. The specific composition (amorphous phase ≥50%, Fe-based phase, Fe3O4 phase <50%) creates locally optimized magnetic properties that reduce losses, enabling miniaturization without sacrificing efficiency.
3Reliability
If Fe3O4 phase content is increased to optimize coercive force, then magnetic properties are improved, but loss characteristic deteriorates
Solution Approach 1:
The patent optimizes the area ratio parameter of Fe3O4 phase to be less than 50% within the multi-phase structure. This parameter control achieves the right balance between coercive force and loss characteristics, preventing excessive Fe3O4 content from causing high losses while maintaining sufficient coercive force through the combined phase structure.
Solution Approach 2:
The patent uses a composite multi-phase material structure where Fe3O4 phase is combined with amorphous phase and Fe-based phase in specific proportions. This composite approach allows the Fe3O4 phase to contribute to coercive force while the other phases compensate for loss characteristics, achieving a balance that would not be possible with Fe3O4 alone.
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 proposed magnetic particle structure effectively reduces coercive force and loss characteristics, enhancing the efficiency and magnetic permeability of magnetic components, while maintaining sufficient packing density and magnetic properties.
Implementation Method 1
The plurality of phases include an Fe-based phase and an Fe3O4 phase. An area ratio of the Fe3O4 phase in which the Fe3O4 phase occupies in the plurality of phases is less than 50%.
Implementation Method 2
an oxide film containing Fe to cover the magnetic metal particle
Data Source
AI summary
A magnetic particle includes a magnetic metal particle having a plurality of phases. The plurality of phases include an Fe-based phase and an Fe3O4 phase. An area ratio of the Fe3O4 phase in which the Fe3O4 phase occupies in the plurality of phases is less than 50%.