SBIR Phase II: High Performance Nano-Fe/SiO2 Soft Magnetic Cores Based on Exchange Coupling

Inframat Corp, Farmington CT

Investigators

Abstract

This Small Business Innovation Phase II project is directed toward optimizing and scaling up fabrication of exchange coupled Fe/ceramic nanocomposites for high performance soft magnetic applications. In Phase I, Inframat Corporation took pioneering steps to develop Fe/ceramic magnetic nanocomposites, which resulted in significant improvements over microsized ferrites including higher saturation magnetization and lower power loss. The design of the Fe/ceramic nanocomposite is based on an exchange coupling effect between neighboring nanoparticles, where Fe nanoparticles are uniformly distributed within an insulating ceramic matrix. Successful Phase I efforts have provided the scientific and technological groundwork for further magnetic nanocomposite technology advancement in Phase II. The proposed Phase II program scales-up the Fe/ceramic nanocomposite technology performed in Phase I. Emphasis is on rapid commercialization of nanocomposite cores. Key Phase II milestones include (1) scale-up of the demonstrated chemical synthesis into pilot-scale production, (2) demonstration of prototype cores having desirable magnetic properties through exchange coupling, and (3) demonstration of high performance prototype DC-to-DC converters using the exchange coupled magnetic nanocomposite cores. Phase II participants include Ceramic Magnetics, UConn, Villanova Univ., Georgia Tech, and a converter specialist, Colonel William McLyman. Ceramic Magnetics has pledged $75,000 cost share to the Phase II and will carry a $250,000 follow-on funding.