Soft Magnetic Alloy Phase Design for Low-Loss Power Cores
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current magnetic materials for power supply circuits in electronic equipment face challenges in reducing core loss and improving power efficiency, particularly in achieving high saturation magnetic flux density and low coercivity while maintaining high resistivity.
Innovation Solution
A soft magnetic alloy with a composition of Fe and P, featuring a Fe-rich phase and a Fe-poor phase with a P concentration 1.5 times higher in the Fe-poor phase, and a specific grain size range for Fe-based nanocrystallines, which enhances saturation magnetic flux density, reduces coercivity, and increases resistivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional Fe-based amorphous materials are used, then saturation magnetic flux density can be achieved, but coercivity remains high and resistivity is insufficient
Solution Approach 1:
The patent applies local quality by creating distinct Fe-rich phases and Fe-poor phases with different compositions and properties within the same alloy. The Fe-rich phases provide high saturation magnetic flux density, while the Fe-poor phases contribute to low coercivity and high resistivity, resolving the contradiction between these magnetic properties.
Solution Approach 2:
The patent employs composite materials by combining multiple phases (Fe-rich amorphous phase, Fe-poor amorphous phase, and Fe-based nanocrystalline phase) with different magnetic and electrical characteristics. This multi-phase composite structure enables the alloy to simultaneously achieve high saturation magnetic flux density, low coercivity, and high resistivity.
2Strength
If Fe-based amorphous alloy is used, then saturation magnetic flux density is improved, but core loss reduction is insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the concentration ratios of elements (Fe, P, B, Si, Cu, and optional elements) within specific ranges. By adjusting compositional parameters and phase distribution, the alloy achieves optimal balance between saturation magnetic flux density and core loss reduction.
Solution Approach 2:
The multi-phase composite structure enables simultaneous optimization of magnetic properties (high saturation flux density) and energy loss characteristics (low core loss) through the synergistic effects of different phases with complementary properties.
3Power
If magnetic material with high saturation magnetic flux density is used, then power supply efficiency can be improved, but resistivity remains insufficient
Solution Approach 1:
The patent applies local quality by concentrating P elements preferentially in Fe-poor phases, creating regions with high resistivity that reduce eddy current losses. This local enrichment of P in specific phases allows the material to maintain high power supply efficiency while achieving sufficiently high overall resistivity.
Data Source
AI summary
A soft magnetic alloy has a main component of Fe. The soft magnetic alloy contains P. A Fe-rich phase and a Fe-poor phase are contained. An average concentration of P in the Fe-poor phase is 1.5 times or larger than an average concentration of P in the soft magnetic alloy by number of atoms.