Soft Magnetic Powder Coating for Permeability and Withstand Voltage
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Solution Overview
Problem
Soft magnetic metal dust cores face challenges in achieving both high magnetic properties and withstand voltage due to the trade-off between insulation coating thickness and magnetic permeability, where thick coatings reduce magnetic properties and thin coatings lead to dielectric breakdown.
Innovation Solution
A soft magnetic metal powder with a coating part that includes a compound of P, Si, Bi, or Zn, incorporating a soft magnetic metal fine particle inside the coating layer to enhance insulation while maintaining magnetic properties, with a thickness of 1 nm to 100 nm and an aspect ratio of 1:2 to 1:10000 for the soft magnetic metal fine particle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation coating layer is made thicker to suppress eddy current and improve withstand voltage, then the insulation property is improved, but the magnetic permeability decreases
Solution Approach 1:
The patent embeds soft magnetic metal fine particles inside the insulation coating layer, creating a nested structure where the coating part contains both the insulation compound and the fine particles. This allows the coating to be thicker for better insulation while the embedded fine particles contribute to magnetic properties, resolving the contradiction between insulation thickness and magnetic permeability.
Solution Approach 2:
The coating part is formed as a composite material containing both the insulation compound and soft magnetic metal fine particles. This composite structure provides both insulation properties (from the compound) and magnetic properties (from the fine particles), allowing simultaneous improvement of withstand voltage and maintenance of magnetic permeability.
2Loss of energy
If the proportion of magnetic ingredients is increased to improve magnetic properties, then the magnetic permeability is improved, but the insulation property deteriorates due to particle contact
Solution Approach 1:
The patent extracts the insulation function from the coating material itself and places it inside the coating layer as embedded fine particles. This allows the coating to provide both insulation (through the compound matrix) and magnetic properties (through the embedded particles), preventing particle contact while maintaining high magnetic permeability.
3Loss of energy
If the insulation coating layer is made thinner to maintain magnetic properties, then the magnetic permeability is maintained, but dielectric breakdown occurs easily
Solution Approach 1:
By nesting soft magnetic metal fine particles within the insulation coating layer, the patent enables the use of thicker coating layers without sacrificing magnetic permeability. The embedded fine particles contribute to magnetic properties while the surrounding compound matrix provides enhanced insulation, preventing dielectric breakdown even with increased thickness.
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 solution effectively balances magnetic permeability and withstand voltage, ensuring both properties are maintained even with a thicker insulation coating, preventing dielectric breakdown and maintaining good DC superimposition properties.
Implementation Method 1
a surface of the soft magnetic metal particles is covered by a coating part having an insulation property
Implementation Method 2
the coating part includes a soft magnetic metal fine particle
Data Source
AI summary
A soft magnetic metal powder comprising soft magnetic metal particles including Fe, wherein a surface of the soft magnetic metal particle is covered by a coating part having an insulation property, and the coating part includes a soft magnetic metal fine particle.