Abstract
In this study, we demonstrate a hybrid multimodal soft magnetic composite (SMC) comprising gas-atomized spherical amorphous powder (AP) and carbonyl-iron powder (CIP), and present its enhanced electromagnetic properties. CIP is selectively incorporated into voids between AP, and deforms during compression, effectively reducing the pores, resulting in high packing density of the core, where CIP magnetically bridges AP and helps magnetic domain rotation much efficiently. The hybrid SMC with the addition of 20 wt.% CIP showed constant effective permeability of 57 up to 1 MHz, a remarkable 63% increase compared with the AP core, while DC bias superimposing retention level of 61% was secured with the help of high magnetization of CIP. In addition, the effect of SiO2 surface insulation, prepared by the sol-gel process, on the high-frequency magnetic properties of hybrid SMCs, was also evaluated. It is thus revealed that the high-frequency dynamic loss of the hybrid core, originating from intra-particle eddy current loss and anomalous loss component, and inter-particle eddy currents are negligibly small. We believe that our approach using AP/CIP multimodal hybrid SMCs is an effective way of achieving high permeability as well as high DC bias characteristics at high frequencies. This process will be highly beneficial for the miniaturization of power inductors.
Highlights
As mobile devices such as smartphones and tablet PCs become widely distributed and thinner and lighter, miniaturization of the electronic components inside the devices is urgently required [1]
We demonstrate a hybrid multimodal soft magnetic composite (SMC) comprising gas-atomized spherical amorphous powder and carbonyl-iron powder (AP/CIP hybrid SMCs), and present enhanced electromagnetic properties of this material, including significantly enhanced effective permeability and DC bias characteristics, compared with AP cores without
Results and Analyses ofDiscussion the properties of the original AP and CIP were performed prior to the SMC
Summary
As mobile devices such as smartphones and tablet PCs become widely distributed and thinner and lighter, miniaturization of the electronic components inside the devices is urgently required [1]. Essential components for power management of electronic devices, must be miniaturized; they must operate at high frequencies and inevitably be capable of dealing with high currents Following this trend, it is necessary to supply magnetic powder cores with high permeability, low core loss, and good DC bias characteristics, especially at high frequencies. Soft magnetic amorphous powders prepared by gas or water atomization have spherical shapes with average particle sizes of 15~100 μm [8], ensuring isotropic magnetic properties and high packing density; these materials are suitable for powder cores, especially for work at frequencies over 200 kHz. With evenly distributed micro-gaps between particles, amorphous powder SMCs provide modulated permeability as well as minimized magnetic field leakage around the core. The effect of surface insulation on the core density and permeability, and the high-frequency core-loss in terms of inter-particle eddy current loss, were systematically investigated
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