Basic Characterization of Magnetocoated Wire Fabricated Using Spray Method

Recently, there has been an increase in the demand for high-efficiency miniature electronic equipment such as personal computers. Therefore, using high drive frequencies and reducing copper loss have become important in meeting the demand. In this paper, we propose the use of magnetocoated wires (MCWs) for coil windings fabricated using the spray method. MCW coils reduce the resistance due to the proximity effect because a magnetic layer leads a magnetic field. As a result, the resistances of the copper wire (COW) and MCW coils at the frequency f = 2.5 MHz are 668 and 447 mQ, respectively, which show a reduction of 33% from resistance of COW to MCW. The resistances of the MCW coils at the frequency f = 20 kHz and the current I = 8 A decreased by 10% compared with the resistances of the COW. The temperature increment of the MCW coils decreased by 5 °C compared with that of COW. This was because MCWs decrease the ac resistance of coils. The magnetic saturation was examined in detail using the finite-element method from the measured value of complex permeability. From the calculated magnetic field and measured magnetization curve, we show the absence of magnetic saturation in coils of nine turns.