Improved Soft Magnetic Materials for High Power Density Electrical Machines

This STTR Phase I proposal is aimed to develop high induction soft magnetic nano-composites (SMNC) capable of high power operations at frequency between 20 kHz to 10 MHz. With Spectrum Magnetics’ proprietary technique, leveraged with research excellence in magnetic materials at the University of Delaware, we will develop magnetic nano-entities of large aspect ratio which effectively eliminates undesired demagnetization factor. Subsequent consolidation of laminated magnetic nano-entities leads to SMNC cores, which is a nano-scale version of the conventional laminated soft FeSi (silicon steel) cores. Our process greatly simplifies the manufacture procedures and reduces the cost. BENEFIT: The successful development of proposed soft magnetic nanocomposites (SMNC) will fill the frequency (20 kHz – 10 MHz) and induction level gaps (B>0.4T) that cannot be satisfied with existing commercial soft magnetic materials, either metallic amorphous ribbons or ferrites. The proposed SMNC have huge potentials for applications in motors and generators, high frequency and high power inductors, switching power supply applications such as DC-DC convertors, and electromagnetic aircraft launch system (EMALS). The total market size for switching power supply alone is about US$26.7B in 2007 and is projected to grow to US$31B in 2011.