Additive Manufacturing of Toroid Inductor for Power Electronics Applications

Yan, Yi; Moss, Jim; Ngo, Khai D. T.; Mei, Yunhui; Lu, Guo-Quan

doi:10.1109/tia.2017.2729504

Cited by 45 publications

(11 citation statements)

References 18 publications

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“…A commercial multi-extruder 3D printer was utilized by Yan et al for fabricating magnetic components in an effort to simplify integration processes in power electronic circuits [13]. The feasibility of AM processes to fabricate complex magnetic components by printing a conductive winding along with a magnetic core has been reported in the technical literature [14]. Additionally, improvements in magnetic properties were reported by adjusting the feed paste formulation, its flow characteristics and AM process parameters.…”

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confidence: 99%

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

Nagarajan

Kamkar

Schoen

et al. 2020

JMMP

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Polymer bonded permanent magnets find significant applications in a multitude of electrical and electronic devices. In this study, magnetic particle-loaded epoxy resin formulations were developed for in-situ polymerization and material jetting based additive manufacturing processes. Fundamental material and process issues like particle settling at room temperature and elevated temperature curing, rheology control and geometric stability of the magnetic polymer during the thermal curing process are addressed. Control of particle settling, modifications in rheological behavior and geometric stability were accomplished using an additive that enabled the modification of the formulation behavior at different process conditions. The magnetic particle size and additive loading were found to influence the rheological properties significantly. The synergistic effect of the additive enabled the developing of composites with engineered magnetic filler loading. Morphological characterization using scanning electron microscopy revealed a homogenous particle distribution in composites. It was observed that the influence of temperature was profound on the coercive field and remanent magnetization of the magnetic composites. The characterization of magnetic polymers and composites using rheometry, scanning electron microscopy, X-ray diffraction and superconducting quantum interference device (SQUID) magnetometry analysis enabled the correlating of the behavior observed in different stages of the manufacturing processes. Furthermore, this fundamental research facilitates a pathway to construct robust materials and processes to develop magnetic composites with engineered properties.

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confidence: 99%

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

Nagarajan

Kamkar

Schoen

et al. 2020

JMMP

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“…It has been used to optimize electromagnetic aspects in several studies [94]- [97]. Currently, it is gaining interest owing to its additive manufacturing, which makes it possible to realize complex shapes [98]- [101] even for HF magnetics and their thermal management enhancement.…”

Section: Thermal Management Of Pmcsmentioning

confidence: 99%

Thermal Modeling of Planar Magnetics: Fundamentals, Review and Key Points

2023

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High-frequency and high-power density converters are essential for many applications such as automotive and more electric aircraft. To improve power density, planar magnetic components are increasingly used in power electronic converters owing to their advantages, such as less high-frequency losses, repeatability, and better thermal performance compared to conventional wound components. Considerable attention has been paid to their electrical performance. However, the thermal aspects are essential for enhancing completely their performance. Currently, there is an increasing interest in these critical aspects of high-density power converters. This paper presents a literature review of studies on the thermal modeling of planar magnetics. The papers were organized according to the model type and analyzed to highlight their merits and limitations. A multicriteria comparison of the studied papers was performed. Moreover, the key points and issues related to the thermal modeling are addressed to guide designers in enhancing the thermal aspects of planar magnetic components.INDEX TERMS Planar magnetics, High frequency magnetics, Thermal modeling, high power density.

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“…Within 3D printing, electrical systems can be direct print into complex geometries difficult or impossible to achieve by other means, allowing customization for a specific end user application [207][208][209]. Inductors and transformers, crucial components for most electronics, have been widely investigated [78,210,211]. A fully integrated magnetic inductor was fabricated using extrusion-based 3D printing [210].…”

Section: Transformersmentioning

confidence: 99%

“…Inductors and transformers, crucial components for most electronics, have been widely investigated [78,210,211]. A fully integrated magnetic inductor was fabricated using extrusion-based 3D printing [210]. Magnetic and conductive pastes were deposited into 3D structures for power electronics circuits, followed by heating for curing polymers.…”

Section: Transformersmentioning

confidence: 99%

Advances in 3D printing of magnetic materials: Fabrication, properties, and their applications

et al. 2022

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Magnetic materials are of increasing importance for many essential applications due to their unique magnetic properties. However, due to the limited fabrication ability, magnetic materials are restricted by simple geometric shapes. Three-dimensional (3D) printing is a highly versatile technique that can be utilized for constructing magnetic materials. The shape flexibility of magnets unleashes opportunities for magnetic composites with reducing post-manufacturing costs, motivating the review on 3D printing of magnetic materials. This paper focuses on recent achievements of magnetic materials using 3D printing technologies, followed by the characterization of their magnetic properties, which are further enhanced by modification. Interestingly, the corresponding properties depend on the intrinsic nature of starting materials, 3D printing processing parameters, and the optimized structural design. More emphasis is placed on the functional applications of 3D-printed magnetic materials in different fields. Lastly, the current challenges and future opportunities are also addressed.

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Additive Manufacturing of Toroid Inductor for Power Electronics Applications

Cited by 45 publications

References 18 publications

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites

Thermal Modeling of Planar Magnetics: Fundamentals, Review and Key Points

Advances in 3D printing of magnetic materials: Fabrication, properties, and their applications

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