Soft Magnetic Alloy Composition for Low Coercivity
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Solution Overview
Problem
Current soft magnetic alloys do not achieve sufficient reduction in coercivity and improvement in magnetic permeability, which are necessary for reducing core loss and enhancing efficiency in electronic and communication devices.
Innovation Solution
A soft magnetic alloy with a specific compositional formula ((Fe(1−(α+β))X1αX2β)(1−(a+b+c+e))MaBbPcCue)1−fCf, where X1 is Co or Ni, X2 includes Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, O, and rare earth elements, and M is Nb, Hf, Zr, Ta, Ti, Mo, W, V, with specific atomic percentage ranges, that forms Fe-based nanocrystals with a body-centered cubic structure, achieving low coercivity and high magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional soft magnetic alloy compositions are used, then basic magnetic properties are maintained, but coercivity cannot be sufficiently reduced and magnetic permeability cannot be sufficiently improved
Solution Approach 1:
The patent applies parameter changes by precisely controlling the compositional ratios of multiple elements (Fe, Co, Ni, Al, Mn, Si, B, Cu, Ti, Zr, Nb, Ta, W, Mo, V, P, C) within specific ranges. This systematic parameter optimization enables simultaneous reduction of coercivity and improvement of magnetic permeability, resolving the contradiction between reducing core loss and maintaining compositional manageability
Solution Approach 2:
The patent creates a composite soft magnetic alloy incorporating multiple transition metal elements (Co, Ni, Mn, Cu, Ti, Zr, Nb, Ta, W, Mo, V) alongside Fe, B, and other elements. This multi-element composite composition achieves synergistic effects that reduce coercivity and improve magnetic properties while maintaining reasonable compositional complexity through defined concentration ranges
2Strength
If alloy composition is optimized for high saturation magnetic flux density, then magnetic strength is improved, but coercivity reduction and permeability improvement are insufficient
Solution Approach 1:
The patent applies local quality by assigning specific functional roles to different element groups within the alloy: Fe provides base magnetic properties and saturation flux density, while Co/Ni enhance permeability, Al/Mn/Si control coercivity, and B/Cu/Ti/Zr/Nb/Ta/W/Mo/V refine microstructure. This localized functional distribution enables simultaneous optimization of saturation magnetic flux density and magnetic permeability
3Loss of energy
If coercivity is reduced to lower core loss, then energy efficiency is improved, but achieving sufficient coercivity reduction while maintaining high permeability is difficult
Solution Approach 1:
The patent applies preliminary action by incorporating specific elements (B, Cu, Ti, Zr, Nb, Ta, W, Mo, V) in predetermined concentrations that pre-condition the alloy microstructure during solidification and heat treatment. This preliminary compositional design facilitates subsequent coercivity reduction and permeability enhancement through controlled phase transformation and grain structure development
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 alloy exhibits high saturation magnetic flux density, low coercivity, and increased magnetic permeability, leading to reduced core loss and improved efficiency in magnetic devices, enabling energy savings and device miniaturization.
Implementation Method 1
The above mentioned soft magnetic alloy according to the present invention tends to easily have the Fe-based nanocrystal alloy by carrying out a heat treatment
Implementation Method 2
The above mentioned soft magnetic alloy according to the present invention tends to easily have the Fe-based nanocrystal alloy by carrying out a heat treatment
Data Source
AI summary
A soft magnetic alloy including a compositional formula of ((Fe(1−(α+β))X1αX2β)(1−(a+b+c+e))MaBbPcCue)1−fCf, wherein X1 is one or more selected from the group consisting Co and Ni, X2 is one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, O, and rare earth elements, “M” is one or more selected from the group consisting of Nb, Hf, Zr, Ta, Ti, Mo, W, and V, 0.030<a≤0.14, 0.028≤b≤0.20, 0≤c≤0.030, 0<e≤0.030, 0<f≤0.040, α≥0, β≥0, and 0≤α+β≤0.50 are satisfied.