AC軟磁性材料近幾年來已被應用在電子及汽車零件上，本研究將藉由粗細鐵粉的混合，且在鐵粉表面上生成一層具有電氣絕緣效果的皮膜層，以維持基材的高磁通密度並降低能量轉換過程中的鐵損為本研究目標。實驗結果顯示鐵粉經磷化處裡90s且磁蕊經200℃退火處理下所製成的壓粉磁蕊中，細粉與粗粉的比例為2：1時所製成之壓粉磁蕊最符合本研究之要求。此外，磷化處理後鐵粉表面所生成皮膜結構為 Zn3(PO4)2 ，此一絕緣層不僅使鐵材保有優越的磁通密度而且可以提高壓粉磁蕊的電阻率，提高頻率使用範圍並降低渦電流損失。另一方面，藉由退火處理可提升磁通密度，但退火溫度超過200℃時，由於黏結劑的損耗因而造成電阻率降低，因而有可能造成磁通密度為10kG時的鐵損在測試頻率為200kHz內大幅度的提升且會造成磁通密度為10kG下的交流導磁率下降。在相同磷化時間、相同退火溫度，但不同比例的粗細鐵粉所製成的壓粉磁蕊中，雖然細粉含量的增加會使電阻率提升並抑制渦電流損失的產生，但隨著細粉含量的增加磁滯損失也隨之上升。

In recent years, remarkable advances have been made in AC soft magnetic materials of compressed powder cores for electronic and automotive applications. By mixing iron powders of two different particle sizes, the goals of this study are to achieve high magnetic fluxes and reduce total iron losses of pure iron powders coated with insulated layers. The results indicate that the compressed powder cores conform to the study goals as the best magnetic performances were achieved when the ratio of fine iron powder and coarse iron powder was 2：1. With a phosphate treatment, the structure of the insulated layer coated on iron particle surface was Zn3(PO4)2. It could not only maintain the magnetic fluxes of pure iron, but also enhance the electrical resistivity of compressed cores by reducing the eddy current loss, which allows a wider frequency range of applications. In addition, annealing treatment after compression could raise magnetic fluxes, but an annealing temperature higher than 200℃ caused the decomposition of binder, resulting in decreased electrical resistivity. For the compressed powder cores with same phosphate treatment time and annealing temperature, the eddy current loss decreased, due to the increase in electrical resistivity, while the hysteresis loss increased with increase in the content of fine iron powder.

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