Title Page
Abstract
Contents
Chapter 1. Introduction 15
1.1. Scope of Thesis 15
1.2. Soft Magnetic Material 16
1.2.1. Classification of Soft Magnetic Materials 16
1.2.2. Kinds of Soft Magnetic Materials 17
1.3. Soft Magnetic Metal Alloy Powder for High-Frequency Application 21
1.3.1. Method of Manufacturing Soft Magnetic Metal Alloy Powder 21
1.3.2. Manufacturing of Amorphous Metal Alloy Powder 21
1.4. Research Trends of the Inductor 24
1.4.1. Inductor Definition 24
1.4.2. Trends in Inductor Research for High-Current Density Power Supplies 26
References 28
Chapter 2. Effects of Surface Oxidation on the Magnetic Properties of Fe-Based Amorphous Metal Powder Made by Atomization Methods 29
2.1. Introduction 29
2.2. Amorphous Alloy Powder Manufactured by Atomization Method 30
2.3. Experimental Procedure 31
2.4. Results and Discussion 32
2.5. Conclusion 45
References 46
Chapter 3. Improvement of Core Loss of Amorphous Alloy Powders Coated with Low Melting Temperature Glass Frits 50
3.1. Introduction 50
3.1.1. Introduction 50
3.1.2. Control of Core Loss 51
3.2. Experimental procedure 53
3.3. Results and Discussion 56
3.4. Conclusion 72
References 73
Chapter 4. A Study on the Manufacture of Inductors for Eco-Friendly Automobiles Using Magnetic Paste Using Amorphous Alloy Powder 76
4.1. Introduction 76
4.2. OBC PFC Inductor for Elector Vehicles 79
4.3. Mold Inductor using Magnetic Paste 81
4.3.1. Method of Manufacturing Magnetic Paste 81
4.3.2. Evaluation of Magnetic Properties of Magnetic Paste 83
4.4. Results and Discussion 86
4.5. Conclusion 106
References 107
Chapter 5. Conclusion and Future Works 109
Appendix A. United States Patent 112
TABLE 2.1. Oxidation content of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powders. 34
TABLE 2.2. Eddy current loss (Pev), hysteresis loss (Phv), and total core loss (Pcv) as a function of the frequency in Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder.[이미지참조] 44
TABLE 3.1. Glass frits glass transition temperature (Tg) and Softening Temperature (Ts).[이미지참조] 64
TABLE 3.2. Eddy current loss (Pev), hysteresis loss (Phv), and total core loss (Pcv) of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder-coated glass frits.[이미지참조] 70
TABLE 4.1. Inductor simulation data value according to inductor raw material. 99
Fig. 1.1. Magnetic material type. 18
Fig. 1.2. Process of making metal powder. 23
Fig. 2.1. X-ray diffraction patterns of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ alloy powders. 33
Fig. 2.2. SEM images of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder. 35
Fig. 2.3. TEM images of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder. 37
Fig. 2.4. TEM EDX results of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder by HSWSA-F. 38
Fig. 2.5. Saturation magnetization properties of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder. 40
Fig. 2.6. Initial permeability as a function of the frequency of Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder. 41
Fig. 3.1. Schematic diagram of factors that control core loss of soft magnetic materials. 52
Fig. 3.2. Schematic diagram of the high-speed water screen atomization (HSWSA) method. 55
Fig. 3.3. SEM images and XRD pattern of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder using the high-speed water atomization method. 57
Fig. 3.4. DSC curve of Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ alloy powders. 58
Fig. 3.5. Structure of Phosphate glass doped Al₂O₃. 60
Fig. 3.6. Schematic of eddy current loss control factors. 62
Fig. 3.7. SEM image of Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous metal powder coated with glass frits powder. 66
Fig. 3.8. Powder resistance of Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ alloy powders coated with glass frits. 67
Fig. 3.9. Initial permeability as a function of frequency in Fe₉₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powders coated with glass frits. 69
Fig. 4.1. Electronic vehicle parts using an inductor for power supply modules. 78
Fig. 4.2. OBC PFC circuit diagram 80
Fig. 4.3. Schematic diagram of the manufacturing method of magnetic paste. 82
Fig. 4.4. Schematic of horsfield's packing model. 84
Fig. 4.5. Sample image for evaluating magnetic paste initial permeability and DC bias characteristics. 85
Fig. 4.6. SEM image and XRD pattern of the Fe₉₂.₃Si₃.₅B₃.₀C₀.₇P₀.₅ amorphous powder manufactured for magnetic paste. 87
Fig. 4.7. SEM image of (a) Fe-Si-Al alloy powder and (b) Fe-Si alloy powder manufactured by gas atomization method. 88
Fig. 4.8. Initial permeability property of magnetic paste according to raw material powder. 90
Fig. 4.9. DC bias characteristics of magnetic paste according to raw material powder. 92
Fig. 4.10. Inductor schematic diagram using magnetic metal powder core. 94
Fig. 4.11. Process flow chart of manufacturing an inductor for an automobile. 96
Fig. 4.12. Schematic diagram of Inductor simulation using maxwell program for OBC PFC. 98
Fig. 4.13. Image of OBC PFC inductors manufactured using magnetic paste. 101
Fig. 4.14. Inductance of OBC PFC inductor using magnetic pastes according to raw material powder. 103
Fig. 4.15. DC Bias characteristics of OBC PFC inductor using magnetic pastes according to raw material powder. 104