Local adaptive insulation in amorphous powder cores with low core loss and high DC bias via ultrasonic rheomolding

H Z Li; Y Q Yan; W S Cai; L Y Li; A Yan; L H Liu; J Ma; H B Ke; Q Li; B A Sun; W H Wang; C Yang

doi:10.1038/s41467-024-53592-9

Local adaptive insulation in amorphous powder cores with low core loss and high DC bias via ultrasonic rheomolding

Nat Commun. 2024 Nov 4;15(1):9510. doi: 10.1038/s41467-024-53592-9.

Authors

H Z Li¹, Y Q Yan², W S Cai¹, L Y Li³, A Yan¹, L H Liu¹, J Ma⁴, H B Ke², Q Li⁵, B A Sun^{6

7}, W H Wang^{2

8}, C Yang⁹

Affiliations

¹ National Engineering Research Center of Near-net-shape Forming for Metallic Materials, Guangdong Provincial Key Laboratory for Processing and Forming of Advanced Metallic Materials, South China University of Technology, Guangzhou, China.
² Songshan Lake Materials Laboratory, Dongguan, China.
³ Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, Shenzhen University, Shenzhen, China.
⁴ Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, Shenzhen University, Shenzhen, China. majiang@szu.edu.cn.
⁵ State Key Laboratory of Advanced Materials and Electronic Components, Guangdong Fenghua Advaced Technology Holding CO., LTD, Zhaoqing, China.
⁶ Songshan Lake Materials Laboratory, Dongguan, China. Sunba@iphy.ac.cn.
⁷ Institute of Physics, Chinese Academy of Sciences, Beijing, China. Sunba@iphy.ac.cn.
⁸ Institute of Physics, Chinese Academy of Sciences, Beijing, China.
⁹ National Engineering Research Center of Near-net-shape Forming for Metallic Materials, Guangdong Provincial Key Laboratory for Processing and Forming of Advanced Metallic Materials, South China University of Technology, Guangzhou, China. cyang@scut.edu.cn.

Abstract

Amorphous powder cores are promising components for next-generation power electronics. However, they present inherent challenges of internal air gaps and stresses during cold compaction, which significantly deteriorate soft magnetic properties. Here, we report the formation of a local adaptive insulation structure of biconcave lens in amorphous powder cores by ultrasonic rheomolding. Consequently, compared with conventional cold-compacted powder cores, the ultrasonic rheomolded powder cores offer significant simultaneous improvements in the permeability from 31.3-32.4 to 41.8-43.3 and the direct-current bias performance from 69.4-69.7% to 87.4-87.8% (7960 A/m), thereby overcoming the trade-off between permeability and direct-current bias performance. In particular, their core losses are as low as 13.73-15.45 kW/m³, approximately one twentieth of that of the cold-compacted powder cores (282.84-304.03 kW/m³) at a magnetic field of 100 mT and 100 kHz. The biconcave-lens insulation structure can effectively buffer the impact of high mechanical stress on the magnetization of magnetic powder particles, allowing for the ultrasonic rheomolded powder cores to maintain better magnetization efficiency and consequently resulting in excellent soft magnetic properties under the cooperative effect of very low internal stresses and low porosity. The ultrasonic rheomolded powder cores can be used as alternative core components in next generation miniaturized power electronics.