Metal Powder Core With Copper Dispersion For Low Core Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing metal powder cores for power supply applications face challenges in achieving a balance between high saturation magnetic flux density and low core loss, with current materials either having low saturation magnetic flux density or high hysteresis loss due to crystal magnetic anisotropy and magnetostriction.
Innovation Solution
A metal powder core is developed by dispersing Cu powder among soft magnetic material powder containing pulverized and atomized Fe-based soft magnetic alloy powders, with a preferred composition and structure that includes an amorphous structure, α-Fe crystalline phase, and an insulation coating, and a fabrication method involving mixing, pressure forming, and heat treatment to optimize density and magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional soft magnetic materials are used to achieve high saturation magnetic flux density, then the saturation magnetic flux density is improved, but the core loss increases due to crystal magnetic anisotropy and magnetostriction
Solution Approach 1:
The patent employs a composite powder structure combining Fe-Si-Al-based soft magnetic powder with specific insulation coatings. This composite approach allows achieving high saturation magnetic flux density while suppressing core loss through the insulation treatment that reduces eddy current effects and controls hysteresis behavior.
Solution Approach 2:
The patent optimizes specific material parameters including the composition ratios of Fe-Si-Al alloy, particle size distribution, and insulation coating thickness. By carefully controlling these parameters, the material achieves both high saturation magnetic flux density and low core loss, resolving the trade-off between these two properties.
2Loss of energy
If insulation treatment is performed on soft magnetic powder surface to suppress eddy current loss, then eddy current loss is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent employs self-forming insulation mechanisms where the insulation coating is applied through processes that integrate naturally with the powder manufacturing flow. The insulation treatment is designed to occur as part of the standard production sequence, reducing the need for separate complex processing steps while still achieving effective eddy current suppression.
3Quantity of substance
If metal powder core density is increased to improve magnetic properties, then saturation magnetic flux density is improved, but the compaction pressure required increases
Solution Approach 1:
The patent optimizes particle size distribution and shape characteristics of the soft magnetic powder to achieve high packing density at lower compaction pressures. By controlling these physical parameters of the powder, the material achieves high saturation magnetic flux density without requiring excessive compaction pressure, thus resolving the contradiction between density and pressure requirements.
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 results in a metal powder core with reduced core loss and improved strength, suitable for applications requiring high efficiency and size reduction in power supply apparatuses.
Implementation Method 1
electric resistance is improved by the insulation treatment so that eddy current loss is suppressed
Implementation Method 2
electric resistance is improved by the insulation treatment so that eddy current loss is suppressed
Implementation Method 3
a fabrication method involving mixing, pressure forming, and heat treatment to optimize density and magnetic properties
Implementation Method 4
pressure forming is performed on this so that a metal powder core is obtained in which the density is improved
Data Source
AI summary
Provided are: a metal powder core having a configuration suitable for core loss reduction and strength improvement; a coil component employing this; and a fabrication method for metal powder core. The metal powder core is obtained by dispersing Cu powder among soft magnetic material powder comprising pulverized powder of Fe-based soft magnetic alloy and atomized powder of Fe-based soft magnetic alloy and then by performing compaction. The fabrication method for metal powder core includes: a mixing step of mixing together soft magnetic material powder containing thin-leaf shaped pulverized powder of Fe-based soft magnetic alloy and atomized powder of Fe-based soft magnetic alloy, Cu powder, and a binder and thereby obtaining a mixture; a forming step of performing pressure forming on the mixture obtained at the mixing step; and a heat treatment step of annealing a formed article obtained at the forming step.