Wholesale OEM Powder Core

How do powder pump powder core manufacturers choose magnetic materials (such as ferrite, metal powder, etc.) and insulating media in the powder core?

1. Selection of magnetic materials
Magnetic permeability:
Magnetic permeability is an important parameter to measure the magnetic conductivity of materials. Materials with high magnetic permeability can better concentrate the magnetic field and improve the inductive capacity and energy storage capacity of the inductor. Common magnetic materials with high magnetic permeability include ferrite, iron powder core and sendust powder core.
Select magnetic materials with appropriate magnetic permeability according to the needs of specific applications. For example, for applications that require high inductance values ​​and energy storage capacity, materials with higher magnetic permeability can be selected.
Saturation magnetic induction intensity:
Saturation magnetic induction intensity determines the carrying capacity and stability of the material under strong magnetic fields. Materials with high saturation magnetic induction intensity can provide higher current carrying capacity and stability, and are suitable for high-frequency and high-current application scenarios.
When selecting, it is necessary to consider the maximum current and magnetic field strength in the application to ensure that the saturation magnetic induction intensity of the selected material can meet the requirements.
Temperature stability:
Temperature has an effect on both the magnetic permeability and saturation magnetic induction intensity of magnetic materials. Therefore, choosing a magnetic material with good temperature stability can ensure the performance stability and reliability of the magnetic powder core at different temperatures.
For applications that need to work in a wide temperature range, special attention should be paid to the temperature stability of the magnetic material.
Cost and processability:
Different magnetic materials have different costs and processing difficulties. When choosing, it is necessary to comprehensively consider the balance between cost and performance. For some special application scenarios, it may be necessary to choose a material with higher cost but better performance.
At the same time, it is also necessary to consider the processability and customization of the material to meet the needs of specific shapes and sizes.
2. Selection of insulating medium
Insulation performance:
The main function of the insulating medium is to isolate eddy currents and reduce the eddy current loss of the magnetic powder core. Therefore, it is necessary to select a dielectric material with good insulation performance.
Parameters such as insulation resistance and dielectric constant of the insulating medium have an important influence on the performance of the magnetic powder core. When choosing, it is necessary to ensure that the insulation performance of the selected medium can meet the application requirements.
Addition amount:
The addition amount of the insulating medium has an impact on the properties of the magnetic powder core, such as magnetic permeability and resistivity. Generally speaking, as the amount of insulating medium added increases, the magnetic permeability decreases and the resistivity increases.
Therefore, when selecting the amount of insulating medium to be added, it is necessary to weigh it according to the needs of the specific application. The optimal range of addition can be determined through experimental testing.
Compatibility with magnetic materials:
The insulating medium needs to have good compatibility with the selected magnetic material to ensure that the overall performance of the magnetic powder core is stable and reliable. When selecting, the interaction and possible influence between the medium and the magnetic material need to be considered.
3. Comprehensive selection steps
Clear application requirements:
First, it is necessary to clarify the application scenarios and requirements of the magnetic powder core, including inductance value, current carrying capacity, frequency range, temperature range, etc.
Screening magnetic materials:
Select magnetic materials with appropriate magnetic permeability, saturation magnetic induction intensity, temperature stability and cost-effectiveness according to application requirements.
Select insulating medium:
Select the appropriate insulating medium and its addition amount according to the characteristics of the magnetic material and application requirements.
Experimental verification:
Verify through experimental testing whether the combination of the selected magnetic material and insulating medium meets the application requirements. Adjust and optimize according to the test results.
Determine the final plan:
Determine the final magnetic powder core design plan based on the experimental verification results, including the type and specification of the magnetic material, the type and addition amount of the insulating medium, etc.

How can powder pump magnetic powder core suppliers ensure that powder pump magnetic powder cores can maintain good performance in harsh environments?

1. Material selection and optimization
Magnetic powder materials: Select high-quality ferromagnetic powder particles to ensure that they can maintain stable magnetic properties in harsh environments. At the same time, consider the particle size and morphology of the powder particles, as well as their impact on the effective magnetic permeability of the magnetic powder core.
Insulating medium: Select a suitable insulating medium to effectively isolate eddy currents and protect the magnetic powder core from environmental factors. The content and performance of the insulating medium are also key factors affecting the performance of the magnetic powder core.
2. Design optimization
Structural design: Optimize the structural design of the magnetic powder core to reduce the mechanical stress and chemical erosion that may be suffered in harsh environments. For example, a more robust shell or additional protective measures can be used to protect the magnetic powder core.
Heat dissipation design: Considering the high or low temperature effects that may be caused by harsh environments, a reasonable heat dissipation system is designed to ensure that the magnetic powder core can maintain an appropriate temperature range during operation.
3. Manufacturing process
Pressing process: During the pressing process, appropriate pressure and rate are used to ensure that the density and strength of the magnetic powder core meet the requirements while avoiding excessive defects and dislocations.
Annealing treatment: Reasonable annealing temperature and time can completely remove the internal stress generated by the magnetic powder core during the pressing process, and improve the effective magnetic permeability and performance of the magnetic powder core. However, too high annealing temperature will burn the insulating layer coated on the surface of the magnetic powder, so the annealing process parameters need to be strictly controlled.
Atmosphere control: During the annealing process, inert gas is selected as the protective atmosphere to prevent the magnetic powder core from oxidizing at high temperatures.
4. Maintenance and care
Regular inspection: Regularly inspect the magnetic powder core to promptly discover and deal with possible problems, such as insulation damage and magnetic performance degradation.
Environmental monitoring: Monitor the working environment of the magnetic powder core to ensure that parameters such as ambient temperature, humidity, and chemical gas concentration are within an acceptable range.
Cleaning and maintenance: Regularly clean the surface of the magnetic powder core and the surrounding environment to prevent dust, dirt and other impurities from damaging the magnetic powder core.
5. Other precautions
Installation and debugging: Ensure that the installation position of the magnetic powder core is correct and the connection with other equipment is firm and reliable. During the debugging process, be careful to avoid excessive impact or vibration on the magnetic powder core.
Safe use: Comply with relevant safety operating procedures to ensure that no damage is caused to operators or equipment during use.