Look out for Sintex’s components made of soft magnetic composites (SMCs), for use in electrical coils, sensors, stators, speakers and as the back iron in rotors. The SMC material is made from a very pure iron powder with a surface coating on each particle. This electrically insulating surface ensures a high electrical resistance and further ensures that the eddy current loss is almost negligible, as well as ensuring a good relative permeability and high magnetic saturation.
SMCs are attractive in applications that require low losses, particularly at high frequencies. The benefits of SMCs increase with the magnetic frequency. At frequencies exceeding 200Hz, SMCs exhibit lower losses than standard 0.5mm-thick laminated iron plates, benefitting both the maximum power rating and power consumption.
Furthermore, the isotropic magnetic properties of SMCs provide new opportunities. They are made from compressed powder, allowing for complex geometries, as well as making the components lighter and cheaper. The complex 3D geometries and alternative flux paths also permit a high fill factor for copper windings.