Soft Magnetic Powder SiO2 Surface Layer for Hybrid Car Reactors
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Solution Overview
Problem
Conventional magnetic cores made from composite materials with Fe-based soft magnetic powder lack superior magnetic properties, such as constant magnetic permeability and low energy loss, and mechanical strength, especially when exposed to strong vibrations like in hybrid car reactors.
Innovation Solution
The development of soft magnetic powder with a SiO2 layer and a surface layer composed of silicone or phosphate, which is uniformly dispersed in resin, forming a magnetic core with a volume percentage of 50% to 85% soft magnetic powder, ensuring constant magnetic permeability and enhanced mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Fe-based soft magnetic powder with insulating layer is used in magnetic core, then insulation between particles is ensured, but magnetic properties such as constant permeability and low energy loss are not achieved
Solution Approach 1:
The patent applies composite materials by creating a multi-layer surface structure on soft magnetic particles consisting of a SiO2 layer and a surface layer containing phosphate and silicone. This composite structure provides both insulation (through SiO2 and phosphate) and improved magnetic properties (through silicone modification), resolving the contradiction between insulation and energy loss.
Solution Approach 2:
The patent changes the chemical composition parameters of the surface layer by incorporating both phosphate and silicone materials. This parameter modification allows the surface layer to simultaneously provide insulation properties and reduce energy loss, achieving constant permeability and low iron loss while maintaining particle insulation.
2Reliability
If Fe-based soft magnetic powder with insulating layer is used in magnetic core, then insulation between particles is ensured, but mechanical strength under strong vibration is insufficient
Solution Approach 1:
The patent uses composite materials with a dual-layer surface structure (SiO2 layer + surface layer containing phosphate and silicone) that provides both insulation and mechanical strength. The combination of different materials creates a robust surface structure that maintains particle insulation while withstanding strong vibrations in hybrid car reactors.
3Reliability
If soft magnetic powder with complex surface structure is used, then magnetic properties and mechanical strength are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the SiO2 layer on soft magnetic particles before final assembly into the magnetic core. This pre-prepared surface structure simplifies the overall manufacturing process, as the complex multi-layer surface is created in advance during particle production rather than during core assembly.
Solution Approach 2:
The SiO2 layer forms naturally on the soft magnetic particle surfaces through oxidation processes, providing self-service by creating part of the required surface structure without additional manufacturing steps. This natural formation reduces the complexity of creating the multi-layer surface structure.
4Reliability
If higher volume percentage of soft magnetic powder is used in composite material, then magnetic properties are improved, but mechanical strength and processability decrease
Solution Approach 1:
The patent changes the surface composition parameters of the soft magnetic particles by incorporating phosphate and silicone in specific ratios within the surface layer. This parameter optimization allows for better interparticle bonding and resin adhesion, enabling the use of higher soft magnetic powder content (50-85 vol%) while maintaining mechanical strength and processability.
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 magnetic core exhibits excellent magnetic properties with constant permeability and reduced iron loss, along with improved mechanical strength and productivity in manufacturing, making it suitable for applications like hybrid car reactors.
Implementation Method 1
soft magnetic particles in the soft magnetic powder include a SiO2 layer formed on a surface of the particles
Implementation Method 2
an annealing step of annealing the base powder at a temperature of 600° C. or more and 1000° C. or less for 0.5 hours or more and 3 hours or less
Data Source
AI summary
Provided is soft magnetic powder constituted by an Fe alloy containing Si, in which soft magnetic particles of the soft magnetic powder include a SiO2 layer formed on a surface of the particles, and a surface layer formed directly on the SiO2 layer. The surface layer includes a first material that constitutes a matrix and a second material that is dispersed in the matrix. The first material is silicone or phosphate, and the second material is silicone or phosphate and is different from the first material.