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中国物理学会期刊

环氧树脂包覆对Fe基纳米晶软磁复合材料高频损耗的影响机制

Mechanisms Governing High-Frequency Loss in Fe-Based Nanocrystalline Soft Magnetic Composites via Epoxy Resin Coating

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  • 高频损耗(Pcv)是制约软磁复合材料(SMCs)在下一代高频、小型化电力电子系统中广泛应用的性能瓶颈,而通过绝缘包覆剂与工艺参数的协同优化,则是抑制此类损耗的核心策略。本文以Fe73.5Si13.5B9Nb3Cu1纳米晶粉末为磁性基体,系统研究了环氧树脂包覆对SMCs绝缘完整性及高频磁性能的影响。适量环氧树脂包覆(2 wt.%,EP2)能够显著改善当前SMCs的Pcv,其在20 mT/1000 kHz与50 mT/100 kHz下分别为628 mW/cm3与283 mW/cm3。Bertotti损耗分离证实,增加包覆含量在轻微降低涡流损耗的同时,显著增大磁滞损耗;而后者在总损耗中占比的升高是导致体系Pcv增大的主因。适量环氧树脂包覆在降低磁粉芯孔隙率、改善致密度的同时,形成了均匀、连续且致密的包覆层,有效抑制了颗粒间的局部偏聚,最终使EP2样品的磁滞损耗与涡流损耗同步达到最优,实现了Pcv的最低值。通过精准调控环氧树脂的包覆含量,无需额外借助多层包覆或界面改性等复杂策略,即可实现各损耗分量的协同调控。该策略为高频大功率磁性元件的损耗调控提供了有效路径。

     

    High-frequency core loss (Pcv) constitutes a critical bottleneck restricting the widespread application of soft magnetic composites (SMCs) in next-generation, high-frequency, miniaturized power electronic systems. To effectively suppress such losses, the synergistic optimization of insulating coatings and processing parameters represents a core strategic approach. In this work, Fe73.5Si13.5B9Nb3Cu1 nanocrystalline powders with a mean particle size of 12.98 μm are employed as the magnetic matrix. A series of SMC toroidal cores with varying epoxy resin (EP) coating contents is then fabricated through a sequential process of powder insulation, uniaxial compaction at 1800 MPa, and subsequent stress-relief annealing at 450 ℃. The effect of EP coating content on the insulation integrity and high-frequency magnetic performance of SMCs is systematically investigated. At an optimal content of 2 wt.% (designated as EP2), the Pcv is significantly reduced, yielding values of 628 mW/cm3 at 20 mT/1000 kHz and 283 mW/cm3 at 50 mT/100 kHz. These loss characteristics are superior to those of most reported SMCs under equivalent testing conditions. Bertotti loss separation reveals that increasing the EP coating content slightly reduces eddy-current loss (Pe) while substantially increasing hysteresis loss (Ph). Specifically, upon increasing the EP content from 2 wt.% to 3 wt.%, the contribution of Pe to Pcv decreases from 60% to 48%, whereas that of Ph increases from 40% to 52%. This indicates a transition of the dominant loss mechanism from Pe to Ph, with the rising proportion of the latter being the primary cause for the overall increase in Pcv. The proper EP coating content reduces porosity and enhances the densification of the magnetic powder core. Meanwhile, it forms a uniform, continuous, and dense coating layer that effectively suppresses localized agglomeration between particles. This combined effect enables the EP2 sample to achieve an optimal balance between Ph and Pe, thereby yielding the minimum Pcv. Through precise control of the EP coating content, synergistic regulation of individual loss components can be realized without resorting to complex strategies such as multi-layer coating or interfacial modification. This approach thus provides an effective and straightforward pathway for loss management in high-frequency, high-power magnetic components.

     

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