Particle-based, anisotropic composite materials for magnetic cores

Patent metadata

Field	Value
Publication number	US-11158450-B2
Application number	US-201916442699-A
Country	US
Kind code	B2
Filing date	Jun 17, 2019
Priority date	Jun 17, 2019
Publication date	Oct 26, 2021
Grant date	Oct 26, 2021

Abstract

A magnetic core comprises an anisotropic, composite material, which itself includes a matrix material (e.g., a dielectric, non-magnetic material, preferably a paramagnetic material), and magnetically aligned, ferromagnetic particles. The latter may for instance include micrometer- and/or nanometer-length scale particles. Such particles form chains of particles within the matrix material, wherein the chains form percolation paths of magnetic conduction. The paths extend along a first direction, whereby the chains extend, each, substantially along this first direction, while being distinct and distant from each other along a second direction that is perpendicular to the first direction and, possibly, to a third direction that is perpendicular to both the first direction and the second direction. Necking bridges are preferably formed between the particles. Related devices (e.g., inductor, amplifiers, transformers, etc.) and fabrication methods are also disclosed.

First claim

What is claimed is:

1. A magnetic core comprising:
an anisotropic, composite material including at least:
a matrix material; and
magnetically aligned, ferromagnetic particles forming chains of said particles within said matrix material, the chains forming percolation paths of magnetic conduction extending along a first direction, whereby the chains extend, each, along the first direction, while being distinct and distant from each other along a second direction that is perpendicular to the first direction, wherein said chains of said magnetically aligned, ferromagnetic particles are arranged in a concentric tori or a racetrack configuration.

2. The magnetic core according to claim 1 , wherein
said particles comprise micrometer-length scale particles.

3. The magnetic core according to claim 1 , wherein
said particles include first particles of a first type and second particles of a second type, the second particles having a smaller average diameter than the first particles, and

the second particles form necking bridges between the first particles along the first direction.

4. The magnetic core according to claim 3 , wherein
said first particles comprise micrometer-length scale particles, while said second particles comprise nanometer-length scale particles.

5. The magnetic core according to claim 3 , wherein
said first particles and second particles have an average sintering temperature that is less than a melting temperature of the matrix material.

6. The magnetic core according to claim 1 , wherein
said matrix material is a dielectric, non-magnetic material.

7. The magnetic core according to claim 1 , wherein
said composite material comprises between 10 and 50 volume percent of ferromagnetic particles.

8. A magnetic core comprising:
an anisotropic, composite material including at least:
a matrix material; and
magnetically aligned, ferromagnetic particles forming chains of said particles within said matrix material, the chains forming percolation paths of magnetic conduction extending along a first direction, whereby the chains extend, each, along the first direction, while being distinct and distant from each other along a second direction that is perpendicular to the first direction, wherein said matrix material is a paramagnetic material.

9. The magnetic core according to claim 8 , wherein
said chains are substantially arranged according to one of: a parallel line configuration, a configuration of concentric tori, and a racetrack configuration of the chains of particles.

10. The magnetic core according to claim 8 , wherein
said chains of the particles form percolation paths of magnetic conduction extending along both the first direction and a third direction that is perpendicular to both the first direction and the second direction.

11. A magnetic device comprising a magnetic core, the magnetic core comprising:
an anisotropic, composite material including at least:
a matrix material; and
magnetically aligned, ferromagnetic particles forming chains of said particles within said matrix material, the chains forming percolation paths of magnetic conduction extending along a first direction, whereby the chains extend, each, along the first direction, while being distinct and distant from each other along a second direction that is perpendicular to the first direction, and wherein said matrix material is a paramagnetic material.

12. The magnetic device according to claim 11 , wherein
the device is one of: an inductor, a transformer, an amplifier, and a power-supply device.

Assignees

• IBM

Inventors

• Sridhar Arvind Raj Mahankali
• Brunschwiler Thomas
• Ye Suiying
• Del Carro Luca
• Ammann Jens Oliver

Classifications

• H01F3/00

  Cores, Yokes, or armatures (magnetic materials H01F1/00; permanent magnets H01F7/02) · CPC title

• Y10T428/32

  Composite [nonstructural laminate] of inorganic material having metal-compound-containing layer and having defined magnetic layer · CPC title

• H01F1/0306 Primary

  Metals or alloys, e.g. LAVES phase alloys of the MgCu2-type (H01F1/0304 takes precedence) · CPC title

• H01F41/16 Primary

  the magnetic material being applied in the form of particles, e.g. by serigraphy {, to form thick magnetic films or precursors therefor} (H01F41/18 {-H01F41/24} take precedence) · CPC title

• H01F41/02

  for manufacturing cores, coils, or magnets (H01F41/14 takes precedence; for dynamo-electric machines H02K15/00) · CPC title