The application of macroscopic flakes for Fe-6.5%Si bulk magnetics with superior magnetic properties
Inductors are used in power electronics to convert current to different frequency and voltage. They are used extensively from where power is generated all the way to electric vehicles and portable electronic devices. The soft magnetic materials used in the inductors is critical for the performance of the inductors. Currently, a majority of the inductor uses powder core. The use of powder is not ideal as the 3D granule powders generate large demagnetization field working against the applied field, resulting in reduced permeability and efficiency. In this paper, 2D flakes were used to replace the 3D granules as the feedstock for fabricating inductor core. The crystalline Fe-Si based crystalline soft magnetic material in the form of flakes approximately 0.1mm thick, 1mm long and 2mm wide were prepared via melt spinning. The flakes were then coated with insulating materials before compacted into a toroid. The effect of coating thickness and concentration on magnetic properties of the toroidal sample are studied. It was also found that the magnetic cores made by flakes surpass the cores made by same size powder with larger permeability and lower iron losses.