Design of novel soft magnetic composites based on Fe/resin modified with silica

• Soft magnetic composite based on Fe powder and hybrid resin were designed.
• SiO2-nanocomposite polymer matrix represents electrically insulating layer.
• Hybrid polymer improves the thermal and mechanical resistance of composites.
• Homogeneous microstructure provides lower eddy currents in prepared composites.

Mechanical, magnetic and electrical properties of a novel family of soft magnetic composites (SMCs) are studied in detail. The phenolic resin serving as electrical insulating layer in designed Fe/resin composites was modified by 3-glycidoxypropyltrimethoxysilane and tetraethylorthosilicate. The chemical bonding between organic and inorganic parts of a polymer matrix was confirmed by FTIR spectroscopy. Mechanical hardness, flexural strength and distribution of SiO2 nano-particles were substantially improved by using silane coupling agents. The hybrid insulating layer results in a defect-free structure of prepared green compacts, which consequently exhibit a higher permeability and lower eddy current losses.

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