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Ferrite magnetic material development process
The 1960s was an important time in the development of ferrite magnetic materials. The study of the formation atmosphere of MnZn ferrite began in 1960 and played an important role in controlling the concentration of Fe2+ and the valence of Mn ions, paving the way for the preparation of high quality MnZn ferrites.
In the early 1970's, TDK, FDK, Philips and others successively developed the first-generation power ferrite magnetic materials H35/H45/3C81. Although these magnetic materials still have many defects and their power consumption is still relatively high, they are still working. In the 20kHz switching power supply such as color TV line output transformers, switching power supply transformers and other basic conditions, making electronic equipment to throw away the traditional bulky, unstable output analog power, thus achieving the revolutionary progress of electronic equipment power supply.
Due to the large power consumption of the first-generation magnetic materials, they can only be used in switching power supplies whose central operating frequency is about 20 kHz. TDK developed the H7C1 (PC30) material in the early 1980s, which not only increased the central operating frequency to about 100 kHz, but also greatly increased the frequency of the switching power supply, reduced the size of the switching power supply, and the power consumption of the magnetic material With the increase of device temperature, the power consumption shows a decreasing trend, and the loss reaches a minimum when the device temperature reaches about 100° C. It is also known that the temperature coefficient of power consumption is negatively correlated in a certain temperature range. This is another groundbreaking development of ferrite power magnetic materials. The negative power-temperature dependence of 100°C or less does not only accommodate the switching power supply's operating state, keeping the device's lower power consumption, but also making the entire device The heat balance is achieved at lower power consumption, improving the reliability of the entire part. In the same period, FDK developed the H63B (6H10). Siemens developed magnetic materials such as N27, which provided the basis for the rapid development of IC-related industries that thrived during the same period.
In the mid to late 1980s, the development of miniaturization, lightweighting, thinning, and high-efficiency of electronic products became more urgent. The popularity of office equipment such as notebook computers has been increasing. The demand for increased power efficiency has given birth to a new generation of power magnetic materials. Third-generation power magnetic materials (PC40/6H20/N67/3F3, etc.) were introduced, which increased the switching power supply frequency to 100 kHz, while also greatly reducing the power consumption of magnetic materials and improving the efficiency of switching power supplies.
In the late 1990s and early 2000s, TDK, FDK, and other companies have successively developed power-saving ferrite magnetic materials such as PC47/6H45 with ultra-low loss, which consume power at 100kHz, 200mT, and 100°C. Level reached about 250kW/m3, and successfully carried out mass production. In the 1990s, the development trend of miniaturization, light weight, thinness, and high efficiency of the devices has only increased. The operating frequency of switching power supplies is directly at 500 kHz, providing guarantees for the development of smaller sizes. The fourth-generation power ferrite magnetic materials PC50/7H10/3F35/N49 developed by TDK, FDK, Philips, Siemens, etc., have a central operating frequency of 500 kHz or more, meeting the need for light, small and thin switching power supplies. This direction of development has continued to develop rapidly since the beginning of the new century. The improved magnetic materials introduced by several well-known foreign companies can be used in applications from 1MHz to 3MHz.
With the rapid development of ferrite power magnetic materials in the automotive industry, a large number of power ferrites with high saturation magnetic flux densities at high temperatures are required to be used for small and compact transformers with various functions, and at the same time, it can be normal under high temperature conditions. Work, such as the proximity of a motor or other in-vehicle equipment under high-temperature conditions, such as the transformer of a car's front-illuminating headlamp, requires high efficiency of power conversion at high temperatures.
In March 2003, FDK developed 4H45 magnetic material. The saturation magnetic flux density Bs of the magnetic material at 100°C was 450mT, and 4H47 magnetic material was successfully developed in succession. The saturation magnetic flux density Bs was 470mT. This breakthrough has led to a significant increase in power conversion efficiency. It has also enabled FDK's high-Bs magnetic materials to reach the international advanced level, and JSF has started mass production.
In September 2004, TDK introduced PC90 magnetic material, which has a Bs of 450mT at 100°C, which is comparable to that of 4H45. However, its power consumption is 320kW/m3 which is 20% lower than that of 4H45 and close to the PC44 level. These breakthroughs have contributed to a new wave of development in the ferrite industry.
With environmental issues increasingly attracting the attention of the world, EVs (electric cars), HEVs (hybrid cars), FCEVs (fuel cell cars) and other fuel-inefficient cars are rapidly developing. As we all know, the ability of the car to adapt its temperature to various system components is very demanding (temperature span is large), while the DC-DC converter, which is the hub of the new hybrid vehicle power system, must adapt to a wide range of temperature changes. The ferrite magnetic material, which requires its main component, has a very wide temperature adaptability. Although the power consumption of the power consumption valley has been reduced from the earliest 600 to 410, 300, or even 250, although the progress of magnetic materials has advanced, the power consumption of several generations of magnetic materials is high in a wide temperature range extending at room temperature. Horizontally, this led many companies in the industry to develop magnetic materials that have lower power consumption characteristics extending from room temperature to around 100°C. For example, TDK developed a wide-temperature, low-power magnetic material, the PC95.
With the expansion of application fields and the deepening of the development of magnetic materials, under the rigorous demands of users in the IT industry, power electronics, and especially network communications, in order to ensure the stable, reliable, and efficient operation of equipment systems, a concept of novelty and completeness has been established. Gradually dominating the direction of R&D of Mn-Zn ferrite magnetically soft magnetic materials, many new magnetic materials with various properties have been introduced to the market. These magnetic materials have higher saturation magnetic flux density Bs, better DC bias characteristics DC-Bias, lower loss (loss factor tgδ/μ at low magnetic flux density, power consumption Pc at high magnetic flux density ), Lower total harmonic distortion factor (THD), wider frequency of use and broader temperature range, and other comprehensive performance. It is the so-called two-wide (wide temperature, wide frequency), two high (high Bs, high DC-Bias), two low (low loss, low distortion) features. At present, the research of manganese-zinc-ferrite magnetic materials has reached the field of low temperature, high temperature and wider and higher frequency bands.
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