A (Permalloy + NiZn Ferrite) Moldable Magnetic Composite for Heterogeneous Integration of Power Electronics

Soft magnetic moldable composites (SM(2)Cs) would be ideally suited for the integration of magnetic components in power electronic converters because they can be formed into magnetic cores by low-temperature and pressure-less processing. However, most SM(2)Cs have low relative magnetic permeability, typically less than 30, and high core-loss densities at switching frequencies over 1 MHz. To improve their magnetic properties, we combine powders of Permalloy and a NiZn ferrite with an acrylic polymer to formulate a paste of SM(2)C. The paste can be molded and then cured below 200 °C without pressure to form cores with a relative permeability over 35 and a core-loss density at 1 MHz, 30% lower than those of commercial cores. The ease of its processing and high-performance properties makes the SM(2)C a good candidate material for the integration of power magnetics.