Low-Loss, High-Flux Saturation Magnetic Cores for Power Converters

As new and alternative energy sources as added to the energy grid, efficient and low-loss power converters are essential to the storage of energy from these intermittent power sources. However, current magnetic cores limit the efficiency of power converters due to high losses and/or low magnetic flux saturation. Mainstream Engineering Corporation will develop a new magnetic material which exhibits high magnetic flux saturation while maintaining low loss. Mainstream will process existing sheets of soft magnetic materials to improve the properties through a proprietary process. The material is expected to have lower coercivity and electrical resistivity than existing magnetic cores. Mainstream will process soft magnetic sheets to improve magnetic properties and validate the magnetic properties through testing. Mainstream will produce a prototype magnetic core inductor and demonstrate the decreased losses compared to commercial magnetic cores. The specifications for the magnetic core in a power converter will be detailed including the expected size, weight, and losses.