Soft Magnetic Alloy Fe Composition Network Phase
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Solution Overview
Problem
Current soft magnetic alloys used in power supply circuits have high core loss, leading to inefficiencies in energy usage and increased energy consumption, necessitating the development of materials with lower coercivity and higher permeability to enhance power supply efficiency.
Innovation Solution
A soft magnetic alloy with a Fe composition network phase, characterized by regions of higher Fe content linked in a network structure, with specific virtual-line distances and ratios, achieving low coercivity and high permeability, is developed. This alloy is manufactured using methods like the single roll method and gas atomizing, ensuring the formation of an amorphous phase with optimal Fe composition network phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional soft magnetic alloys are used, then the magnetic core can be formed, but the core loss is high leading to low energy efficiency
Solution Approach 1:
The invention creates a non-uniform Fe composition distribution within the soft magnetic alloy, forming a network phase with locally higher Fe content (Fe content maximum points) that are linked together. This local quality variation reduces coercivity and core loss while maintaining overall magnetic properties, directly addressing the energy loss issue.
Solution Approach 2:
The invention introduces a spatial dimension parameter - the virtual-line total distance (10 mm to 25 mm per 1 μm³) and virtual-line average distance (6 nm to 12 nm) - to characterize and control the network phase structure. By controlling the three-dimensional arrangement and connectivity of Fe-rich regions, the invention achieves reduced core loss and improved energy efficiency.
2Loss of energy
If the coercivity is reduced to lower core loss, then energy efficiency improves, but the permeability may be compromised
Solution Approach 1:
The invention creates a composite microstructure within the soft magnetic alloy, consisting of a matrix phase and a network phase with different Fe compositions. The network phase (with Fe content maximum points linked together) provides pathways for magnetic flux that reduce coercivity, while the overall composite structure maintains high permeability through the synergistic arrangement of different composition regions.
Data Source
AI summary
A soft magnetic alloy includes a main component of Fe. The soft magnetic alloy includes a Fe composition network phase where regions whose Fe content is larger than an average composition of the soft magnetic alloy are linked. The Fe composition network phase contains Fe content maximum points that are locally higher than their surroundings. A virtual-line total distance per 1 μm3 of the soft magnetic alloy is 10 mm to 25 mm provided that the virtual-line total distance is a sum of virtual lines linking the maximum points adjacent each other. A virtual-line average distance that is an average distance of the virtual lines is 6 nm or more and 12 nm or less.