Customisable Magnetic Components Using Nanocrystalline Flake Ribbon
type: CreativeWork
description: Power electronics plays a key role in addressing today’s energy challenges. The advancement of wide bandgap (WBG) semiconductors enables power electronic devices to operate at elevated switching frequencies, withstand higher temperatures, achieve greater power density, and deliver improved system efficiency. In accordance with the developing trend of power electronics, there is a growing demand for customising high-performance magnetic components with reduced losses, compact dimensions, lighter weight, and cost-effectiveness. Traditional methods for core customisation are cumbersome, time-consuming, and costly when producing small series of magnetic cores. Recently developed magnetic cores customised through additive manufacturing (AM) have not demonstrated desirable magnetic properties for high-power-density power electronics. In this thesis, a novel nanocrystalline flake ribbon (NFR) is proposed to customise high-performance magnetic components for power electronics in a cost-effective way without high-energy equipment. Conventional nanocrystalline alloys do offer much higher saturation flux density and lower core losses within certain frequency ranges compared to soft ferrites. However, their high-frequency performance is limited by elevated eddy current losses and uneven resin distribution within the laminations. To improve the magnetic properties of nanocrystalline materials and open new possibilities for customising magnetic components, NFR obtained from mechanically crushing the conventional nanocrystalline ribbon is introduced. The magnetic properties of NFR including the DC magnetisation curve, permeability, B-H curve and core losses are well examined. Core loss separation is performed based on Bertotti’s theory, and the classical eddy current loss and excess loss of NFR are compared to conventional nanocrystalline ribbons. To demonstrate the design of high-performance magnetic components using NFRs, this thesis first presents a sandwich-structured inductor…
abstract: Power electronics plays a key role in addressing today’s energy challenges. The advancement of wide bandgap (WBG) semiconductors enables power electronic devices to operate at elevated switching frequencies, withstand higher temperatures, achieve greater power density, and deliver improved system efficiency. In accordance with the developing trend of power electronics, there is a growing demand for customising high-performance magnetic components with reduced losses, compact dimensions, lighter weight, and cost-effectiveness. Traditional methods for core customisation are cumbersome, time-consuming, and costly when producing small series of magnetic cores. Recently developed magnetic cores customised through additive manufacturing (AM) have not demonstrated desirable magnetic properties for high-power-density power electronics. In this thesis, a novel nanocrystalline flake ribbon (NFR) is proposed to customise high-performance magnetic components for power electronics in a cost-effective way without high-energy equipment. Conventional nanocrystalline alloys do offer much higher saturation flux density and lower core losses within certain frequency ranges compared to soft ferrites. However, their high-frequency performance is limited by elevated eddy current losses and uneven resin distribution within the laminations. To improve the magnetic properties of nanocrystalline materials and open new possibilities for customising magnetic components, NFR obtained from mechanically crushing the conventional nanocrystalline ribbon is introduced. The magnetic properties of NFR including the DC magnetisation curve, permeability, B-H curve and core losses are well examined. Core loss separation is performed based on Bertotti’s theory, and the classical eddy current loss and excess loss of NFR are compared to conventional nanocrystalline ribbons. To demonstrate the design of high-performance magnetic components using NFRs, this thesis first presents a sandwich-structured inductor…
author: Li, Xinru
language: eng
keywords: Core Loss, Eddy Current Loss, Inductors, Magnetic Components, Magnetic Device Fabrication, Nanocrystalline Materials, Power Electronics, Transformers
license: https://apollo8-f-pro.lib.cam.ac.uk/bitstreams/3dc9dca5-e72a-4aa6-ac56-fb3e410e1bed/download
license: https://www.rioxx.net/licenses/all-rights-reserved/
date published: 2023-09-01
date modified: 2026-07-22T22:24:06Z
provider: Cambridge University
publisher: Networked Digital Library of Theses and Dissertations
type: WebPage
source organization: University of Cambridge

PropertyValue
property ID: DOI
value: 10.17863/CAM.106857