High-Frequency Properties of Fe-4.5 Wt% Si Powders With an Insulating Layer Synthesized by a Modified Dew-Point Treatment

The frequency for wireless power chargers is in the range of 100-205 kHz when using MnZn ferrite and NiZn ferrite. Compared to ferromagnetic metals, these ferrites have higher resistivity, which reduces the eddy loss at high frequencies, though they also have lower magnetization values that limit the distance and the direction between the receiver and transmitter units. Thus, there is a strong demand for the development of a new metallic magnetic sheet that can suppress the eddy-current loss in the high-frequency range. To meet this demand, a modified dew-point insulation coating method for Fe-4.5 wt% Si powders was assessed and the high-frequency properties of green compacts consisting of these powders were investigated. As a result, a thin high-resistivity layer was successfully coated onto the powders. In addition, both eddy-current loss and hysteresis loss of their compacts were dramatically reduced in the high-frequency region.