Abstract
We developed Fe/FeSiAl soft magnetic powder cores (SMCs) for realizing the miniaturization and high efficiency of an electromagnetic conversion coil in the high-frequency range (∼20 kHz). We found that Fe/FeSiAl SMCs can be formed with a higher density under higher compaction pressure than pure-iron SMCs. These SMCs delivered a saturation magnetic flux density of 1.7 T and iron loss (W1/20k) of 158 kW/m3. The proposed SMCs exhibited similar excellent characteristics even in block shapes, which are closer to the product shapes.
Highlights
The demand for electric automobiles and energy-saving home appliances is increasing to realize a low-carbon society
To evaluate the consolidation characteristics of Fe/FeSiAl soft magnetic powder core (SMC), we studied their density under various compaction pressures (Fig. 4)
The differential permeability of Fe/FeSiAl SMCs improved as the compaction pressure was increased; it is surmised that the improvement was caused by densification
Summary
The demand for electric automobiles and energy-saving home appliances is increasing to realize a low-carbon society. These mount devices require electromagnetic conversion, for which motor mechanisms and power-supply apparatuses are used. Transformers and reactors (Fig. 1) are examples of such conversion devices. Electromagnetic conversion coils, comprising a magnetic core and copper winding, are the core parts of these devices. The demand for inductors exhibiting a high magnetic flux density (Bs) and low iron loss for excellent conversion efficiency, miniaturization, and output improvement is high. SiC devices are becoming increasingly popular; adapting to the trend by applying a high-frequency operating environment for these inductors is necessary
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