Soft Magnetic Metal Powder Oxide Layer for Eddy Current Suppression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Soft magnetic metal powders used in magnetic cores for electronic components often experience core loss due to eddy currents, leading to reduced efficiency and increased power consumption, necessitating the need for improved electrical insulation properties.
Innovation Solution
A soft magnetic metal powder is developed with a structure comprising metal particles coated with an oxidized layer and a further coating part, where the oxidized layer includes oxides of Fe, Si, B, Ca, and Mg, providing enhanced electrical insulation and increased withstand voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If soft magnetic metal powder is used in magnetic core, then saturation magnetization is improved, but core loss increases due to eddy current
Solution Approach 1:
An oxidized part is introduced as an intermediary layer between soft magnetic metal particles. This oxidized layer acts as a mediator that provides electrical insulation while maintaining the magnetic properties of the core, thereby preventing eddy current formation between particles
Solution Approach 2:
The invention uses a composite structure consisting of soft magnetic metal particles combined with an oxidized part containing specific elements (Ca, Mg, Si, B). This composite material approach allows the system to simultaneously achieve high saturation magnetization from the metal particles and low eddy current loss from the insulating oxidized layer
2Reliability
If electrical insulation property is improved to reduce core loss, then withstand voltage is increased, but manufacturing complexity increases
Solution Approach 1:
The oxidized part is formed through a self-oxidation process where the metal particles are exposed to oxygen during manufacturing. This self-service approach allows the insulating layer to form automatically without requiring separate coating or treatment steps, reducing manufacturing complexity while achieving the desired electrical insulation property
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 proposed soft magnetic metal powder significantly reduces core loss by suppressing electrical conduction between particles, thereby enhancing the efficiency and reducing power consumption of electronic components.
Implementation Method 1
an electrical insulation property between the soft magnetic metal particles is required to reduce the core loss
Implementation Method 2
an eddy current is likely to occur in a magnetic core due to electrical conduction between a plurality of soft magnetic metal particles
Implementation Method 3
The oxidized part includes an oxide of at least one kind of element selected from the group consisting of Fe, Si, and B, and at least one kind of element of Ca and Mg
Data Source
AI summary
Provided is a soft magnetic metal powder including a plurality of soft magnetic metal particles. Each of the soft magnetic metal particles includes a metal particle and an oxidized part covering the metal particle. The metal particle includes at least Fe. The oxidized part includes an oxide of at least one kind of element selected from the group consisting of Fe, Si, and B, and at least one kind of element of Ca and Mg. A concentration of Ca or Mg in the metal particle and the oxidized part is maximum in the oxidized part. An average value of a maximum value of the concentration of Ca or Mg in the oxidized part is 0.2 atom % or more.