Realisation of Soft Magnetic Composites for Expanded Use in Future Inductor Applications

Research Project, 2013 – 2014

Iron-powder based nano-coated soft magnetic composites (SMC) represent the most recent innovation in materials for soft-magnetic core applications and provide among the most cost-effective and environmentally-friendly production solutions. The research will focus on the full exploitation of potential of SMC materials given by their 3D magnetic properties through research on base material as well as development of design for power electronic devices with improved performance, especially in the area of the renewable energy generation. This project aims at facilitating future new improved solutions for primary inductor and secondary transformers applications. The expected result of the project is the development of the generic model able to describe how the SMC materials and inductors made thereof should be designed to meet specific application demands. The project is expected to result with design and manufacturing of demonstrators of inductors for various applications including household, wind power or automotive applications. The project will address the materials development (powder surface engineering aspects and consolidation process) by taking laboratory scale test results of base materials and modeling of inductor design to pilot scale production of prototypes. Planned research will cover the tailoring of base powder coating properties and/or consolidation process in order to fulfill design requirements and modeling of design and properties of inductors and transformers (size, loss, core shape, thermal situation, etc.) based on SMC material for particular applications in power electronics.

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