高频低损耗的Fe/亚微米FeNi软磁复合材料

doi:10.15541/jim20230599

无机材料学报 ›› 2024, Vol. 39 ›› Issue (8): 871-878.DOI: 10.15541/jim20230599

高频低损耗的Fe/亚微米FeNi软磁复合材料

何思哲¹(), 王俊舟¹, 张勇¹, 费嘉维¹, 吴爱民¹, 陈意峰², 李强², 周晟³, 黄昊¹()

1.大连理工大学材料科学与工程学院, 辽宁省能源材料及器件重点实验室, 大连 116024
2.广东风华高新科技股份有限公司, 肇庆 526199
3.明新软磁科技(江苏)有限公司, 昆山 215300

收稿日期:2023-12-29 修回日期:2024-03-20 出版日期:2024-08-20 网络出版日期:2024-03-30
通讯作者: 黄昊, 教授. E-mail: huanghao@dlut.edu.cn
作者简介:何思哲(1999-), 男, 硕士研究生. E-mail: HSZ124@mail.dlut.edu.cn
基金资助:
新型电子元器件关键材料与工艺国家重点实验室开放基金(Fenghua-2024-0064)

Fe/Submicron FeNi Soft Magnetic Composites with High Working Frequency and Low Loss

HE Sizhe¹(), WANG Junzhou¹, ZHANG Yong¹, FEI Jiawei¹, WU Aimin¹, CHEN Yifeng², LI Qiang², ZHOU Sheng³, HUANG Hao¹()

1. Key Laboratory of Energy Materials and Devices (Liaoning Province), School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
2. Guangdong Fenghua Advanced Technology Holding Co., Ltd., Zhaoqing 526199, China
3. Mingxin Soft Magnetic Technology (Jiangsu) Co., Ltd., Kunshan 215300, China

Received:2023-12-29 Revised:2024-03-20 Published:2024-08-20 Online:2024-03-30
Contact: HUANG Hao, professor. E-mail: huanghao@dlut.edu.cn
About author:HE Sizhe (1999-), male, Master candidate. E-mail: HSZ124@mail.dlut.edu.cn
Supported by:
Open Fund of State Key Laboratory of Key Materials and Technologies for New Electronic Components(Fenghua-2024-0064)

摘要/Abstract

摘要：

高功率电力电子设备的应用对功率电感的高频电感性能和能量效率提出了更高的要求,迫切需要开发高频低损耗的软磁材料。为降低软磁复合材料的涡流损耗, 获得高频低损耗、大功率的一体成型电感, 通过等离子体炬制备了高纯度亚微米FeNi颗粒, 并采用简化的有限元模型探讨了亚微米FeNi颗粒对软磁复合材料涡流损耗的影响。本工作制备了含不同质量分数亚微米FeNi颗粒的Fe/亚微米FeNi软磁复合材料, 重点讨论了亚微米FeNi颗粒对软磁复合材料及一体成型电感性能的影响。结果表明: 与纯羰基铁粉制备的软磁复合材料相比, 当亚微米FeNi颗粒质量分数为30%时, 环形磁芯代表损耗的磁导率虚部µ″由1.57降至1.36, 降低了13.4%; 一体成型电感在10 MHz条件下的品质因数Q由13升至20, 提高了53.8%, 并且自谐振频率提高了12.7%, 饱和电流由2.148 A升至2.352 A。通过提高材料内阻和减小涡流流动区域的尺寸, 亚微米FeNi颗粒能有效降低涡流损耗, 提高软磁复合材料的高频磁导率稳定性。复合亚微米FeNi颗粒有望低成本、大规模地获得高频低损耗、综合性能良好的一体成型电感。

关键词: 软磁复合材料, 一体成型电感, 亚微米FeNi颗粒, 涡流, 品质因数

Abstract:

Application of high-power electronic equipment requires inductors with greater high-frequency performance and higher energy efficiency than ever, and thus it is urgent to develop new soft magnetic composites to meet these requirements. To reduce the eddy current loss of soft magnetic composites and obtain molded inductors with high working frequency, low loss and high power, high purity submicron FeNi particles were prepared by plasma torch, and effect of these particles on eddy current loss of soft magnetic composites was examined by simplified finite element model. Soft magnetic composites and molded inductors were prepared by mixing carbonyl iron powder and submicron FeNi particles with different mass fractions. The influence of submicron FeNi particles on the properties of soft magnetic composites and molded inductors is analyzed emphatically. With 30% of mass fraction of submicron FeNi particles, the imaginary part of permeability (μ") of the ring core decreases from 1.57 to 1.36 (reduced by 13.4%), compared with that of the soft magnetic composite made by only pure carbonyl iron powder. The quality factor Q of the molded inductors at 10 MHz increases from 13 to 20 (increased by 53.8%), while the self-resonance frequency increases by 12.7% and the saturation current increases from 2.148 A to 2.352 A. Submicron FeNi particles can effectively reduce eddy current loss and improve stability of the high frequency permeability of soft magnetic composites by increasing the internal resistance of materials and reducing the size of eddy current flow region. Therefore, this study demonstrates that compounding submicron FeNi particles is a promising method to obtain molded inductors with high frequency, low loss, and good comprehensive performance at low cost on a large scale.

Key words: soft magnetic composite, molded inductor, submicron FeNi particle, eddy current, quality factor

中图分类号:

TB333

何思哲, 王俊舟, 张勇, 费嘉维, 吴爱民, 陈意峰, 李强, 周晟, 黄昊. 高频低损耗的Fe/亚微米FeNi软磁复合材料[J]. 无机材料学报, 2024, 39(8): 871-878.

HE Sizhe, WANG Junzhou, ZHANG Yong, FEI Jiawei, WU Aimin, CHEN Yifeng, LI Qiang, ZHOU Sheng, HUANG Hao. Fe/Submicron FeNi Soft Magnetic Composites with High Working Frequency and Low Loss[J]. Journal of Inorganic Materials, 2024, 39(8): 871-878.

图/表 11

图1 SMC微观结构模型示意图

Fig. 1 Schematic diagram of microstructure model of SMC (a) Geometric size of Fe and submicron FeNi particles; (b) SMC model of micron Fe powder; (c) SMC model of submicron FeNi particles; (d) SMC model after mixing Fe and submicron FeNi particles

表1 SMC模型的材料属性

Table 1 Material properties of SMC model

Material	Conductivity/ (S·m^-1)	Relative permeability	Relative permittivity
Iron	1.12×10⁷	4000	1
FeNi alloy	1.70×10⁶	8000	1
Matrix	0.1	1	9

图2 羰基铁粉(CIP)和亚微米FeNi颗粒的XRD谱图

Fig. 2 XRD patterns of carbonyl iron powder (CIP) and submicron FeNi particles

图3 两种粉体的SEM照片

Fig. 3 SEM images of two powders (a) CIP; (b) Submicron FeNi particles

表2 羰基铁粉及亚微米FeNi粉体的粒径分布

Table 2 Particle size distributions of CIP and submicron FeNi particles

Material	d₁₀/μm	d₅₀/μm	d₉₀/μm	d_ave/μm
Carbonyl iron powder	2.6	3.7	4.9	3.9
Submicron FeNi powder	0.390	0.668	0.980	0.645

图4 羰基铁粉和亚微米FeNi颗粒的静态磁滞曲线

Fig. 4 Hysteresis loops of CIP and submicron FeNi particles Inset: enlarged view of the part within the orange box

图5 1和100 MHz下SMC微结构中的涡流分布及电流密度模型

Fig. 5 Eddy current distribution and current density |J| in SMC microstructure at 1 and 100 MHz (a, b) SMC model of micron Fe powder; (c, d) SMC model of submicron FeNi particles; (e, f) SMC model after mixing Fe and submicron FeNi particles; Colorful figures are available on website

图6 不同亚微米FeNi颗粒含量的SMCs的横截面SEM照片

Fig. 6 Cross-section SEM images of SMCs with different contents of submicron FeNi particles (a) 0; (b) 100%; (c) 30% (in mass); (d) 70% (in mass)

图7 不同亚微米FeNi颗粒含量的SMCs的压实密度

Fig. 7 Compaction density of SMCs with different contents of FeNi submicron particles

图8 不同亚微米FeNi颗粒含量的SMCs的复数磁导率

Fig. 8 Complex permeability of SMCs with different contents of submicron FeNi particles (a) Real part of permeability, μ'; (b) Imaginary part of permeability, μ"

图9 一体成型电感的结构及性能

Fig. 9 Structure and performance of molded inductor (a, b) Cross-sectional views of molded inductor; (c) Direct current bias performance; (d) Saturation current; (e) Inductance-frequency curves and (f) quality factor-frequency curves of molded inductors with different contents of submicron FeNi particles

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高频低损耗的Fe/亚微米FeNi软磁复合材料

Fe/Submicron FeNi Soft Magnetic Composites with High Working Frequency and Low Loss

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