Abstract
Uneven distribution of magnetic flux in a conventional magnetic core limits improvement of power density of the magnetic component. By making a magnetic core comprising materials with different permeabilities, henceforth called multi-permeability core, a more uniform flux distribution can be achieved without complex configuration and geometry of the core and winding. In this work, we designed a three-ring toroid core to produce a flux uniformity factor, α, defined as B min /B max , in each of the three rings by increasing permeability from inner to outer ring. With the same inductance, volume of the three-permeability toroid core was significantly smaller than that of a single-permeability toroid core. For ease of fabricating multi-permeability magnetic cores, a commercial multi-extruder paste-extrusion 3D printer was explored to process different magnetic pastes into 3D structures. The magnetic pastes were formulated in our laboratory. Two types of magnetic paste systems, a high-temperature (> 900°C) pressure-less sinterable ferrite and a low-temperature (< 250°C) pressure-less curable powdered-iron, were developed and tested in the 3D printer. By varying the magnetic/organic composition in each of the two material systems, we produced pastes that are compatible with the 3D printer and can be processed into core materials with relative permeability ranging from 20 to 70. With the same dimensions, a 3D-printed three-permeability toroid core had a higher inductance than a single-permeability core.
Published Version
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