High energy density electroceramic material with embedded dielectric discontinuities

Abstract

A magnetic core material that stores magnetic energy and reduces magnetic saturation includes a high energy density ceramic member having embedded dielectric discontinuities.

What is claimed is: 
     
         1 . A magnetic core material that stores magnetic energy and reduces magnetic saturation, wherein the magnetic core material comprises dielectric discontinuities embedded within high energy density electroceramic members that:
 minimize Eddy current losses by consisting of any one or all of the flowing atomic elements:
 nickel (Ni), cobalt (Co), zinc (Zn), copper (Cu) titanium (Ti), or chromium (Cr); 
   minimize hysteresis losses by additionally consisting of any one or all of the following atomic elements:
 lead (Pb), strontium (Sr) and magnesium (Mg); and, 
   minimize residual magnetic loss by additionally having a microstructure with a uniform grain size distribution not greater than 7 μm, preferably a uniform grain size distribution in the range of 5-7 μm.   
     
     
         2 . The magnetic core material of  claim 2 , wherein the dielectric discontinuities comprise amorphous silica dielectric. 
     
     
         3 . The magnetic core materials of  claim 2 , wherein high energy density electroceramic members have electrical resistivity ≥10 5  Ω-cm, preferably ≥10 7  Ω-cm. 
     
     
         4 . The magnetic core material of  claim 3  that further minimize Eddy current losses by embedding one or more thin amorphous silica layers having thickness ≤1 μm within the magnetic core material. 
     
     
         5 . The magnetic core material of  claim 2 , wherein the high energy density electroceramic members have relative permeability μ R ≥20, preferably μ R ≥400. 
     
     
         6 . The magnetic core material of  claim 2 , wherein dielectric discontinuities are placed at optimal energy storage locations within the magnetic core material to optimize performance as a magnetic energy storage medium within a magnetic circuit. 
     
     
         7 . The magnetic core material of  claim 6 , wherein dielectric discontinuities within optimal energy storage locations comprise a continuous volume of ultra-low loss amorphous silica dielectric. 
     
     
         8 . The magnetic core material of  claim 6 , wherein dielectric discontinuities within optimal energy storage locations comprise a collection of micro-volumes of amorphous silica dielectric discontinuities rather than a continuous volume. 
     
     
         9 . The magnetic core material of  claim 8 , wherein the collection of micro-volume dielectric discontinuities optimally comprise a patterned three dimensional array of micro-volume dielectric discontinuities that generate a stable distribution of localized micro-volumes of extreme magnetic flux densities that induce maximal inductive coupling with conductive elements of the magnetic circuit when it is reverse cycled. 
     
     
         10 . The magnetic core material of  claim 9 , wherein the magnetic circuit is flyback transformer coils and the optimal energy storage locations within the magnetic core material of a flyback transformer is beneath one or more secondary coil windings. 
     
     
         11 . The magnetic core material of  claim 9 , wherein the magnetic circuit is an energy storing inductor coil and the optimal energy storage locations within the magnetic core material is beneath one or more the coil windings.