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Research and development of Iron-based metal composite bulk magnetic core and its application to gapless reactor and transformer

Research Project

Project/Area Number 15H02233
Research Category

Grant-in-Aid for Scientific Research (A)

Allocation TypeSingle-year Grants
Section一般
Research Field Power engineering/Power conversion/Electric machinery
Research InstitutionShinshu University

Principal Investigator

SATO Toshiro  信州大学, 学術研究院工学系, 教授 (50283239)

Co-Investigator(Renkei-kenkyūsha) FUNAKI Tsuyoshi  大阪大学, 大学院・工学研究科, 教授 (20263220)
SONEHARA Makoto  信州大学, 学術研究院工学系, 准教授 (30456496)
Research Collaborator MURAKAMI Yasushi  信州大学, 学術研究院繊維学系, 教授 (90219907)
Project Period (FY) 2015-04-01 – 2018-03-31
Project Status Completed (Fiscal Year 2017)
Budget Amount *help
¥40,950,000 (Direct Cost: ¥31,500,000、Indirect Cost: ¥9,450,000)
Fiscal Year 2017: ¥7,150,000 (Direct Cost: ¥5,500,000、Indirect Cost: ¥1,650,000)
Fiscal Year 2016: ¥10,270,000 (Direct Cost: ¥7,900,000、Indirect Cost: ¥2,370,000)
Fiscal Year 2015: ¥23,530,000 (Direct Cost: ¥18,100,000、Indirect Cost: ¥5,430,000)
Keywordsパワーエレクトロニクス / SiC/GaNパワーデバイス / DC-DCコンバータ / リアクトル/トランス / 鉄心材料 / コンポジット / リアクトル・トランス / 鉄系メタルコンポジット鉄心材料
Outline of Final Research Achievements

In order to realize the compact and light-weight highly efficient SiC/GaN power device DC-DC converter with a bottle-neck issue on the magnetic core for high frequency reactor and transformer, a novel heat resistant Fe-based metal composite magnetic core with small iron loss at MHz band was developed. The composite magnetic core consisting of 2.6 um size Fe-based amorphous powder with a thermally oxidized surface layer and 200℃ resistant epoxy resin binder exhibited 1/3 smaller MHz band iron loss than that of a bench mark core of Ni-Zn ferrite. The gapless leakage transformer using the Fe-based amorphous composite magnetic core was applied to a GaN power device MHz switching LLC resonant DC-DC converter. The novel magnetic core transformer operated in MHz switching resonant converter with a rating power of 120 W had an efficiency of 97% over and a power density per unit core volume of 90 W/cm3.

Report

(4 results)
  • 2017 Annual Research Report   Final Research Report ( PDF )
  • 2016 Annual Research Report
  • 2015 Annual Research Report
  • Research Products

    (42 results)

All 2018 2017 2016 2015 Other

All Int'l Joint Research (1 results) Journal Article (7 results) (of which Peer Reviewed: 7 results,  Open Access: 4 results) Presentation (29 results) (of which Int'l Joint Research: 5 results,  Invited: 5 results) Book (1 results) Remarks (1 results) Patent(Industrial Property Rights) (3 results)

  • [Int'l Joint Research] アイルランド国立大学ゴールウェイ校(アイルランド)

    • Related Report
      2017 Annual Research Report
  • [Journal Article] Novel method for making surface insulation layer on Fe-based amorphous alloy powder by surface-modification using two-step acid solution processing2018

    • Author(s)
      Kanako Sugimura, Naoki Yabu, Makoto Sonehara, Toshiro Sato
    • Journal Title

      IEEE Transactions on Magnetics

      Volume: 54 Issue: 11 Pages: 1-5

    • DOI

      10.1109/tmag.2018.2834467

    • Related Report
      2017 Annual Research Report
    • Peer Reviewed
  • [Journal Article] Fabrication and evaluation of composite magnetic core using iron-based amorphous alloy powder with different particle-size distribution2018

    • Author(s)
      Naoki Yabu, Kanako Sugimura, Makoto Sonehara, Toshiro Sato
    • Journal Title

      IEEE Transactions on Magnetics

      Volume: 54 Issue: 11 Pages: 1-5

    • DOI

      10.1109/tmag.2018.2832662

    • Related Report
      2017 Annual Research Report
    • Peer Reviewed
  • [Journal Article] Low permeability composite magnetic core transformer with high coupling coefficient and its application to PFM controlled quasi-resonant mode flyback-type DC-DC converter2017

    • Author(s)
      K. Sato, T. Sato, M. Sonehara, H. Takeuchi
    • Journal Title

      Journal of the Magnetics Society of Japan

      Volume: 41 Issue: 6 Pages: 132-139

    • DOI

      10.3379/msjmag.1708R003

    • NAID

      130006192327

    • ISSN
      1882-2924, 1882-2932
    • Related Report
      2017 Annual Research Report
    • Peer Reviewed / Open Access
  • [Journal Article] Surface-Oxidized Amorphous Alloy Powder/Epoxy-Resin Composite Bulk Magnetic Core and Its Application to Megahertz Switching LLC Resonant Converter2017

    • Author(s)
      Kanako Sugimura, Daisuke Shibamoto, Naoki Yabu, Tatsuya Yamamoto, Makoto Sonehara, Toshiro Sato, Tsutomu Mizuno, and Hideaki Mizusaki
    • Journal Title

      IEEE Transactions on Magnetics

      Volume: 53 Issue: 11 Pages: 1-6

    • DOI

      10.1109/tmag.2017.2718042

    • Related Report
      2017 Annual Research Report
    • Peer Reviewed
  • [Journal Article] Fabrication of Metal Composite Magnetic Core Transformer with Surface-Oxidized Carbonyl-Iron Powder and Its Application to the Flyback-Type DC-DC Converter2017

    • Author(s)
      佐藤紘介,杉村佳奈子,佐藤敏郎,曽根原誠,竹内英樹
    • Journal Title

      Transaction of the Magnetics Society of Japan Special Issues

      Volume: 1 Issue: 1 Pages: 44-52

    • DOI

      10.20819/msjtmsj.17TR110

    • NAID

      130005632319

    • ISSN
      2432-0471
    • Related Report
      2017 Annual Research Report
    • Peer Reviewed / Open Access
  • [Journal Article] High permeability and low loss of Ni-Zn-Fe ferrite/metal composite cores in high frequency region2017

    • Author(s)
      Satoshi Mori, Takeshi Mitsuoka, Makoto Sonehara, Toshiro Sato, and Nobuhiro Matsushita
    • Journal Title

      AIP Advances

      Volume: 7 Issue: 5 Pages: 056657-056657

    • DOI

      10.1063/1.4976945

    • Related Report
      2016 Annual Research Report
    • Peer Reviewed / Open Access
  • [Journal Article] Formation of high electrical-resistivity thin surface layer on carbonyl-iron powder2016

    • Author(s)
      K. Sugimura, Y. Miyajima, M. Sonehara, T. Sato, F. Hayashi, N. Zettsu, K. Teshima, H. Mizusaki
    • Journal Title

      AIP Advances

      Volume: 5 Issue: 5 Pages: 055932-055932

    • DOI

      10.1063/1.4944705

    • Related Report
      2015 Annual Research Report
    • Peer Reviewed / Open Access
  • [Presentation] SiC/GaNパワーエレクトロニクスと高周波電力磁気応用のコラボレーション2018

    • Author(s)
      佐藤敏郎
    • Organizer
      平成30年電気学会全国大会シンポジウム「S18 パワーエレクトロニクス励磁の磁性材料の必要性とその研究状況」
    • Related Report
      2017 Annual Research Report
    • Invited
  • [Presentation] サブミクロンアモルファス微粒子合成の基礎検討2017

    • Author(s)
      菱田佳世子,杉村佳奈子,佐藤敏郎,曽根原誠
    • Organizer
      電気学会東海支部学生発表会
    • Place of Presentation
      信州大学(長野市)
    • Year and Date
      2017-01-27
    • Related Report
      2016 Annual Research Report
  • [Presentation] 鉄系メタルコンポジット磁心とその応用2017

    • Author(s)
      佐藤敏郎
    • Organizer
      日本ボンド磁性材料協会軟磁性材料研究会(第14回)
    • Related Report
      2017 Annual Research Report
    • Invited
  • [Presentation] 異なる粉末粒度分布を持つFe系アモルファス粉末を用いたコンポジット磁心の作製と評価2017

    • Author(s)
      藪直希,杉村佳奈子,柴本大輔,稲垣悠太郎,植田大輝,曽根原誠,佐藤敏郎
    • Organizer
      電気学会マグネティックス研究会
    • Related Report
      2017 Annual Research Report
  • [Presentation] 酸溶液処理表面修飾による高抵抗被膜付Fe系アモルファス合金粉の作製と特性評価2017

    • Author(s)
      藪直希,杉村佳奈子,佐藤敏郎,曽根原誠,水嵜英明
    • Organizer
      電気学会マグネティックス研究会
    • Related Report
      2017 Annual Research Report
  • [Presentation] 酸溶液処理表面修飾によるFe系アモルファス合金粉の高抵抗被膜形成2017

    • Author(s)
      藪直希,杉村佳奈子,佐藤敏郎,曽根原誠,水嵜 英明
    • Organizer
      第41回 日本磁気学会学術講演会
    • Related Report
      2017 Annual Research Report
  • [Presentation] サブミクロンFe-Co-B三元系アモルファス磁性微粒子の合成2017

    • Author(s)
      菱田佳世子,杉村佳奈子,佐藤敏郎,曽根原誠
    • Organizer
      第78回 応用物理学会 秋季学術講演会
    • Related Report
      2017 Annual Research Report
  • [Presentation] 鉄系メタルコンポジットバルク鉄心リアクトル・トランスの開発とGaNパワーデバイスMHzスイッチングDC-DCコンバータへの応用2017

    • Author(s)
      佐藤敏郎
    • Organizer
      電気学会マグネティックス研究会
    • Related Report
      2017 Annual Research Report
    • Invited
  • [Presentation] Surface-oxidized amorphous alloy powder/epoxy resin composite bulk magnetic core and its application to MHz band switching LLC resonant converter2017

    • Author(s)
      Kanako Sugimura, Daisuke Shibamoto, Tatsuya Yamamoto, Ryosuke Hirayama, Atsuya Ueno, Kelvin Lai Siong Ong, Naoki Yabu, Makoto Sonehara, Toshiro Sato, Tsutomu Mizuno, Hideaki Mizusaki
    • Organizer
      IEEE International Magnetics Conference (INTERMAG2017)
    • Related Report
      2017 Annual Research Report
    • Int'l Joint Research
  • [Presentation] LLC resonant converter using magnetocated wire and iron-based metal composite core2017

    • Author(s)
      T. Yamamoto, Y. Konno, T. Dobashi, K. Sugimura, T. Sato, Y. Bu, T. Mizuno
    • Organizer
      IEEE International Magnetics Conference (INTERMAG2017)
    • Related Report
      2017 Annual Research Report
    • Int'l Joint Research
  • [Presentation] 表面酸化アモルファス合金粉/エポキシ複合材料磁心トランスの試作とMHzスイッチングLLC共振DC-DCコンバータへの適用2016

    • Author(s)
      平山涼介,杉村佳奈子,山本達也,上野敦也,水嵜英明,佐藤敏郎,曽根原誠,水野勉
    • Organizer
      電気学会マグネティックス研究会
    • Place of Presentation
      九州大学(福岡市)
    • Year and Date
      2016-12-09
    • Related Report
      2016 Annual Research Report
  • [Presentation] Magnetic Properties of Ni-Zn Ferrite / Metal Composite Core in MHz Range2016

    • Author(s)
      Mori Satoshi, Mitsuoka Takeshi, Sato Toshiro, Matsushita Nobuhiro
    • Organizer
      61st Annual Conference on Magnetism and Magnetic Materials (2016 MMM)
    • Place of Presentation
      New Orleans Marriott Hotel (New Orleans, Louisiana, USA)
    • Year and Date
      2016-11-02
    • Related Report
      2016 Annual Research Report
    • Int'l Joint Research
  • [Presentation] SiC/GaN パワーデバイスMHz 帯スイッチングDC-DC コンバータの先導研究2016

    • Author(s)
      佐藤敏郎
    • Organizer
      SiCアライアンス,広報委員会・企画委員会共催研究会
    • Place of Presentation
      虎ノ門ヒルズFRONT 店(東京都)
    • Year and Date
      2016-10-27
    • Related Report
      2016 Annual Research Report
    • Invited
  • [Presentation] 鉄系メタルコンポジット磁心の開発とSiC/GaN パワーデバイスMHzスイッチング電源への応用2016

    • Author(s)
      佐藤敏郎
    • Organizer
      日本ボンド磁性材料協会,第90回技術例会
    • Place of Presentation
      ホテルラングウッド(東京・日暮里)
    • Year and Date
      2016-09-23
    • Related Report
      2016 Annual Research Report
    • Invited
  • [Presentation] 表面酸化鉄系メタルコンポジット磁心トランスの試作とフライバックコンバータへの応用2016

    • Author(s)
      佐藤紘介,杉村佳奈子,佐藤敏郎,曽根原誠
    • Organizer
      第40回日本磁気学会学術講演会
    • Place of Presentation
      金沢大学(金沢市)
    • Year and Date
      2016-09-05
    • Related Report
      2016 Annual Research Report
  • [Presentation] 鉄系メタルコンポジット鉄心材料用アモルファス合金粉の酸化皮膜形成に関する基礎検討2016

    • Author(s)
      杉村佳奈子,平山涼介,水嵜英明,曽根原誠,佐藤敏郎
    • Organizer
      平成28年電気学会基礎・材料・共通部門大会
    • Place of Presentation
      九州工業大学(北九州市)
    • Year and Date
      2016-09-05
    • Related Report
      2016 Annual Research Report
  • [Presentation] フェライトめっきを用いた高周波用途向け軟磁性材料の開発2016

    • Author(s)
      森智史,光岡健,杉村佳奈子,平山涼介,佐藤敏郎,曽根原誠,松下伸広
    • Organizer
      電気学会マグネティックス研究会
    • Place of Presentation
      常盤工業会会館(宇部市)
    • Year and Date
      2016-08-19
    • Related Report
      2016 Annual Research Report
  • [Presentation] 鉄系メタルコンポジット磁心トランスを用いたフライバックコンバータの試作と特性評価2016

    • Author(s)
      佐藤紘介,杉村佳奈子,佐藤敏郎,曽根原誠
    • Organizer
      電気学会マグネティックス研究会
    • Place of Presentation
      常盤工業会会館(宇部市)
    • Year and Date
      2016-08-18
    • Related Report
      2016 Annual Research Report
  • [Presentation] 磁性めっき線と鉄系メタルコンポジット鉄心を用いたLLC共振形コンバータの検討2016

    • Author(s)
      山本達也,杉村佳奈子,佐藤敏郎,曽根原誠,卜穎剛,水野勉,山口豊,狩野知義
    • Organizer
      電気学会マグネティックス/リニアドライブ合同研究会
    • Place of Presentation
      信州大学(長野市)
    • Year and Date
      2016-06-24
    • Related Report
      2016 Annual Research Report
  • [Presentation] 鉄系メタルコンポジット磁心カップルドインダクタの試作と5 V-1 V・30 A,1MHz降圧 DC-DCコンバータへの適用2016

    • Author(s)
      柴本大輔,上野敦也,杉村佳奈子,平山涼介,佐藤紘介,佐藤敏郎,曽根原誠
    • Organizer
      電気学会マグネティックス/リニアドライブ合同研究会
    • Place of Presentation
      信州大学(長野市)
    • Year and Date
      2016-06-23
    • Related Report
      2016 Annual Research Report
  • [Presentation] 表面酸化カルボニル鉄/エポキシ複合材料磁心インダクタを用いた1 MHz降圧DC-DCコンバータの特性評価2016

    • Author(s)
      上野敦也,杉村佳奈子,柴本大輔,佐藤紘介,曽根原誠,佐藤敏郎,金沢秀一
    • Organizer
      平成28年電気学会全国大会
    • Place of Presentation
      東北大学 川内北キャンパス
    • Year and Date
      2016-03-16
    • Related Report
      2015 Annual Research Report
  • [Presentation] Surface-oxidized Carbonyl-iron powder/ epoxy composite bulk magnetic core and its application to a MHz switching buck dc-dc converter2016

    • Author(s)
      Kanako Sugimura, Atsuya Ueno, Daisuke Shibamoto, Kosuke Sato, Makoto Sonehara, Toshiro Sato
    • Organizer
      13th Joint MMM-Intermag Conference
    • Place of Presentation
      Hilton San Diego Bayfront , San Diego, CA, USA
    • Year and Date
      2016-01-11
    • Related Report
      2015 Annual Research Report
    • Int'l Joint Research
  • [Presentation] Formation of high electrical-resistivity thin surface layer on Carbonyl-iron powder (CIP) and thermal stability of nanocrystalline structure and curling magnetic structure of CIP2016

    • Author(s)
      Kanako Sugimura, Yuki Miyajima, Fumitaka Hayashi, Makoto Sonehara, Toshiro Sato, Nobuyuki Zettsu, Katsuya Teshima, Hideaki Mizusaki
    • Organizer
      13th Joint MMM-Intermag Conference
    • Place of Presentation
      Hilton San Diego Bayfront , San Diego, CA, USA
    • Year and Date
      2016-01-11
    • Related Report
      2015 Annual Research Report
    • Int'l Joint Research
  • [Presentation] カルボニル鉄粉の微結晶構造とボルテックス磁気構造の熱履歴変化2015

    • Author(s)
      杉村佳奈子,佐藤敏郎,曽根原誠
    • Organizer
      平成27年度応用物理学会北陸・信越支部学術講演会
    • Place of Presentation
      信州大学 工学部
    • Year and Date
      2015-12-12
    • Related Report
      2015 Annual Research Report
  • [Presentation] カルボニル鉄/エポキシコンポジット鉄心インダクタの試作とGaNパワーデバイスMHz帯スイッチングDC-DCコンバータへの適用2015

    • Author(s)
      杉村佳奈子,上野敦也,柴本大輔,平山涼介,曽根原誠,佐藤敏郎
    • Organizer
      電気学会マグネテッィクス研究会
    • Place of Presentation
      富山高等専門学校
    • Year and Date
      2015-11-26
    • Related Report
      2015 Annual Research Report
  • [Presentation] 鉄系金属微粒子/樹脂複合材料鉄心用高抵抗皮膜付カルボニル鉄粉の作製と特性評価2015

    • Author(s)
      杉村佳奈子,林文隆,佐藤敏郎,曽根原誠
    • Organizer
      東北大学スピニクス特別研究会(協賛;IEEE Magnetics Society, Shin-etsu Chapter)
    • Place of Presentation
      信州大学 工学部
    • Year and Date
      2015-11-19
    • Related Report
      2015 Annual Research Report
  • [Presentation] カルボニル鉄/エポキシ複合材料磁心インダクタを用いた1 MHzスイッチング降圧DC-DCコンバータの特性評価2015

    • Author(s)
      上野敦也,杉村佳奈子,曽根原誠,佐藤敏郎,佐藤絋介
    • Organizer
      電気学会基礎・材料・共通部門大会
    • Place of Presentation
      金沢大学 角間キャンパス
    • Year and Date
      2015-09-17
    • Related Report
      2015 Annual Research Report
  • [Presentation] カルボニル鉄/エポキシ複合材料バルクコアインダクタを用いた1 MHzスイッチング降圧DC-DCコンバータの特性評価2015

    • Author(s)
      上野敦也,杉村佳奈子,曽根原誠,佐藤敏郎,佐藤絋介
    • Organizer
      第39回日本磁気学会学術講演会
    • Place of Presentation
      名古屋大学 東山キャンパス
    • Year and Date
      2015-09-08
    • Related Report
      2015 Annual Research Report
  • [Presentation] 鉄系メタルコンポジット鉄心材料用カルボニル鉄粉の高抵抗皮膜形成に関する基礎検討2015

    • Author(s)
      杉村佳奈子,宮嶋優希,林文隆,曽根原誠,佐藤敏郎,是津信行,手嶋勝弥
    • Organizer
      第39回日本磁気学会学術講演会
    • Place of Presentation
      名古屋大学 東山キャンパス
    • Year and Date
      2015-09-08
    • Related Report
      2015 Annual Research Report
  • [Book] 磁気便覧(日本磁気学会編)2016

    • Author(s)
      佐藤敏郎、他(分担執筆)
    • Total Pages
      904
    • Publisher
      丸善出版
    • Related Report
      2015 Annual Research Report
  • [Remarks] 信州大学先端磁気デバイス研究室ホームページ

    • URL

      http://amdl.shinshu-u.ac.jp/

    • Related Report
      2016 Annual Research Report 2015 Annual Research Report
  • [Patent(Industrial Property Rights)] SiO2含有被膜を備えたSi含有Fe基合金粉及びその製造方法2017

    • Inventor(s)
      佐藤敏郎,曽根原誠,杉村佳奈子,藪直希
    • Industrial Property Rights Holder
      信州大学
    • Industrial Property Rights Type
      特許
    • Industrial Property Number
      2017-151599
    • Filing Date
      2017
    • Related Report
      2017 Annual Research Report
  • [Patent(Industrial Property Rights)] 一軸磁気異方性バルク磁性材料及びその製造方法2017

    • Inventor(s)
      佐藤敏郎
    • Industrial Property Rights Holder
      信州大学
    • Industrial Property Rights Type
      特許
    • Industrial Property Number
      2017-198361
    • Filing Date
      2017
    • Related Report
      2017 Annual Research Report
  • [Patent(Industrial Property Rights)] 磁心材料及びその製造方法2016

    • Inventor(s)
      曽根原誠,佐藤敏郎,村上泰,杉村佳奈子
    • Industrial Property Rights Holder
      信州大学
    • Industrial Property Rights Type
      特許
    • Industrial Property Number
      2016-170452
    • Filing Date
      2016-09-01
    • Related Report
      2016 Annual Research Report

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Published: 2015-04-16   Modified: 2019-03-29  

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