Soft Magnetic Powder Particle Control for Lower Binder Use
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Solution Overview
Problem
Existing soft magnetic powders face challenges in reducing specific surface area and binder usage while maintaining excellent magnetic properties, leading to decreased filling ratios and increased core losses.
Innovation Solution
The development of soft magnetic powders with specific surface area and particle diameter constraints, using a formula S=k{6/(d·ρ)} where 1.0≤k≤4.0 and 1.0≤d≤10.0, which reduces the specific surface area and binder usage, enhancing magnetic permeability and flux density while minimizing eddy current losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a silicon oxide coating layer is formed on soft magnetic metal particles to reduce specific surface area, then binder usage is reduced, but filling ratio decreases and magnetic properties deteriorate
Solution Approach 1:
The patent changes the particle diameter parameter to 1.0≤d≤10.0 μm and controls the specific surface area to satisfy S=k{6/(d·ρ)} with 1.0≤k≤4.0, where ρ is true specific gravity. These parameter changes reduce the specific surface area without requiring silicon oxide coating, thereby reducing binder usage while maintaining high filling ratio and excellent magnetic properties.
2Quantity of substance
If specific surface area is reduced through coating, then binder usage is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent achieves reduced specific surface area through controlling particle diameter (1.0≤d≤10.0 μm) and the parameter k (1.0≤k≤4.0) in the formula S=k{6/(d·ρ)}, eliminating the need for separate coating processes. This simplifies manufacturing while reducing binder usage.
Data Source
AI summary
There is provided a soft magnetic powder containing soft magnetic metal particles satisfying the following formulas (A) (B), and (C),S=k{6/(d·ρ)} (A)1.0≤k≤4.0 (B)1.0≤d≤10.0 (C)in which S [m2/g] indicates a specific surface area, d [μm] indicates an average particle diameter, and ρ [g/cm3] indicates a true specific gravity.