Soft Magnetic Powder Composition for Low-Loss Magnetic Cores
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Solution Overview
Problem
Existing magnetic cores do not achieve a balance between high permeability and low loss, particularly in reducing both copper loss and core loss.
Innovation Solution
A soft magnetic powder with specific composition and surface treatment is used to create a magnetic core, where the soft magnetic particles have a controlled distribution of iron and cobalt, and a surface coating to enhance magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If insulation materials are placed between magnetic particles to reduce eddy current, then core loss is reduced, but hysteresis loss is not sufficiently reduced, resulting in insufficient permeability improvement
Solution Approach 1:
The patent applies local quality by creating a core with non-uniform magnetic particle arrangement and varying insulation material thickness. The core includes a first region with a first filling ratio and a second region with a second filling ratio different from the first, allowing different local regions to optimize for either eddy current reduction or hysteresis loss reduction, thereby simultaneously improving both core loss and permeability.
Solution Approach 2:
The patent uses composite materials by combining magnetic particles with specific insulation materials (such as oxide coatings or organic insulation layers) to create a multi-material core structure. This composite approach allows the core to benefit from both the magnetic properties of the particles and the insulating properties of the materials, reducing both eddy current and hysteresis loss.
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 improved permeability and reduced core loss, achieving a balance between high magnetic efficiency and low energy dissipation.
Implementation Method 1
a soft magnetic particle containing at least one selected from the group consisting of iron and cobalt
Data Source
AI summary
A soft magnetic powder including a soft magnetic particle containing at least one selected from the group consisting of iron and cobalt: when the soft magnetic particle satisfies the relation of σFeCo(S)−σFeCo(C)≤−0.005, when an element distribution is divided into multiple grids to calculate a sum of content ratios of iron and cobalt in each grid, and a standard deviation of the sum of the content ratios is represented by σFeCo(S) where a population is the grids, and an element distribution is divided into multiple grids to calculate a sum of content ratios of iron and cobalt in each grid, and a standard deviation of the sum of the content ratios is represented by σFeCo(C) where a population is the multiple grids.