FEM analysis of magnetic flake composites

A composite comprised of layered flake-like magnetic particles embedded in an insulating medium has been proposed as a low permeability, low loss core material. This would be an alternative to “distributed air gap” compressed powder cores that are widely used for inductors in power applications. Since the lowest loss metallic materials are manufactured in the form of very thin sheets, the particles after pulverizing would be in the form of flakes. The effective permeability and average core loss have been computed for model systems of flake composites in a two-dimensional approximation. The core loss is modeled by eddy current dissipation in the low-frequency limit, where the conductor thickness is much less than the skin depth. It is found that useful values of permeability should be obtained for a modest filling fraction of magnetic material, in contrast to the powder cores which require a value close to unity. The core loss will scale as the inverse of filling fraction, with a small additional enhancement due to perpendicular field components. It is thus expected that useful core materials may be attainable without the necessity of large compaction forces.