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

Purpose and goal

The main target of the project was to develop generic model allowing to establish the most important design parameters for soft magnetic composite (SMC) material and large-size inductors with SMC cores to meet specific application demands. Characteristics of the SMC surface coating, electromagnetic simulation platform, testing procedures and required tailoring of the process for robust design and manufacturing of the large-size inductors (up to 100 A) were established. Validity of the developed concept was tested on three physical demonstrators manufactured in the project.

Results and expected effects

Development of the structured material and design concept for manufacturing of high-performance large-size induction cores based on SMC material is the most relevant result of the project. Improved solutions for novel inductor applications developed provide value-added solutions for active front-end (AFE) converters that are used for connection of e.g. renewable energy sources as solar and wind power to the power grid. This represents a significant enlargement of applications for SMC inductors and hence market increase for both, SMC powder and applications of SMC inductors.

Approach and implementation

Developed relationship between SMC material properties and processing conditions with magnetic performance allows implementation of the project results in the batch process during coming couple of years. Demonstrator, developed utilizing established material and design platform, possesses designed electromagnetic performance with significantly lower manufacturing costs that allows to foreseen widening of the application field for larger inductors in the near future. Already during last year Höganäs AB tripled production of SMC inductors due to increasing market need.