Impact of Morphological and Structural Properties of Submicron Core–Shell Fe-Silica Particles on High-Current Power Converter Performance in Electronics

As the demand for energy-efficient solutions grows in industries such as electric vehicles and renewable energy systems, the need for high-current power converters, powder core inductors, has become increasingly critical. These converters are essential for managing the flow of energy while maintaining efficiency under demanding conditions. However, achieving the necessary performance, particularly in terms of energy storage and minimizing energy losses, requires advanced materials with tailored magnetic properties. This study addresses these needs by introducing a novel class of magnetic materials, i.e., submicrometer-sized silica-coated iron (Fe@SiO₂) particles. These particles are produced through a one-step aerosol process, enabling precise control over particle morphology, size, and structural characteristics. The tuned Fe@SiO₂ particles demonstrated improved packing density and saturation current as well as reduced eddy current losses, significantly boosting the stability and efficiency of power converters to meet the demands of modern high-current electronic systems. This research highlights the importance of advanced magnetic materials in the ongoing evolution of power electronics, offering new possibilities for more efficient and reliable power conversion systems in a range of applied electronic technologies.