1. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by New Polymer-Bonded Magnetic Materials Invention By Professor Eric Cheng

2. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by Magnetic Powder Preparation Raw materials with different mass ratios are vigorous mixed for about 2 minutes The mixture is then sintered at 1300 °C for 950 minutes. And cooled down to room temperature within 30 minutes. Resultant Powder

3. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by Polymer-bonded Materials Preparation General procedure I for blending of magnetic powders with PMMA

4. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by Polymer-bonded Materials Preparation General procedure II for blending of magnetic powders with PMMA

5. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by Polymer-bonded Materials Preparation PMMA:Co( 30%:70%)PMMA:Ni( 30%:70%)PMMA:NiZn(50:50:0) ( 40%:60%) Images of the extrusive composites (Polymer-bonded Magnetic Materials)

6. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by Polymer-boned Cores Making Procedure for Making Ring Cores Hot Press Machine Core Mould Polymer-bonded Cores Polymer-bonded Materials

7. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by Mould Design and Making Ring core (OD25) mould and samples

8. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by EI40 core mould and samples Mould Design and Making

9. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by Mould Design and Making U15 core mould and samples

10. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 10 Mechanical and Strength Properties Testing Impact Resistance Test Schematic of the general testing mechanism for Impact Resistance Measurement

11. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 11 Mechanical and Strength Properties Testing Impact Resistance Test “V” shape sample used in the testing for Impact Resistance Measurement

12. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 12 Mechanical and Strength Properties Testing Rockwell Hardness Measurement Schematic of the testing mechanism on a Rockwell hardness tester

13. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 13 Mechanical and Strength Properties Testing Rockwell Hardness Measurement Measurement results for Rockwell Hardness test Samples ’ Composition Rockwell Hardness Number, HR Rockwell Superficial 30-T 30 kg, 1/16 In ball Rockwell Standard F 60 kg, 1/16 In ball Rockwell Standard B 100 kg, 1/16 In ball 60%Ni – 40% PMMA 75768081―― 60%Co – 40% PMMA 77758182―― 70%Ni – 30% PMMA 8283102103―― 70%Co – 30% PMMA 9092112111―― 60%NiZn – 40% PMMA 94 119121―― 90%Ni – 10% PMMA ――1031059695

14. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 14 Mechanical and Strength Properties Testing Tensile Strength Measurement Shape of the samples for tensile strength measurement.

15. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 15 Mechanical and Strength Properties Testing Tensile Strength Measurement Measurement results for tensile strength measurement Sample composition Tensile Strength (N/mm 2 ) Sample composition Tensile Strength (N/mm 2 ) 60%Ni – 40 %PMMA 15.9360%NiZn – 40 %PE29.56 70%Ni – 30 %PMMA 16.0170%NiZn – 30 %PE45.21 60%Co – 40 %PMMA 20.3480%NiZn – 20 %PE60.17 70%Co – 30 %PMMA 21.8690%NiZn – 10 %PE89.28 60%NiZn – 40 %PMMA 20.15 90%NiZn – 10 %UHMWPE 300 192.28 70%NiZn – 30 %PMMA 22.35 90%NiZn – 10 %UHMWPE 500 220.22

16. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 16 Mechanical and Strength Properties Testing Tensile Strength Measurement Typical photos of the tensile strength measurement results

17. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 17 Mechanical and Strength Properties Testing Resistance to Compression Measurement The resistance to compression measurement results Sample composition Resistance to Compression (N/mm 2 ) Sample composition Resistance to Compression (N/mm 2 ) 60%Ni – 40 %PMMA 56.3160%NiZn – 40 %PE39.82 70%Ni – 30 %PMMA 59.5770%NiZn – 30 %PE42.66 60%Co – 40 %PMMA 43.6280%NiZn – 20 %PE45.20 70%Co – 30 %PMMA 47.8390%NiZn – 10 %PE44.01 60%NiZn – 40 %PMMA 57.91 90%NiZn – 10 %UHMWPE 300 121.30 70%NiZn – 30 %PMMA 58.24 90%NiZn – 10 %UHMWPE 500 136.17

18. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 18 Mechanical and Strength Properties Testing Resistance to Compression Measurement Typical photos of the resistance to compression measurement results

19. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 19 Mechanical and Strength Properties Testing Radial Crushing Strength Measurement Radial crushing strength measurement results Sample composition Radial Crushing Strength (N/mm 2 ) Sample composition Radial Crushing Strength (N/mm 2 ) 60%Ni – 40 %PMMA 68.2260%NiZn – 40 %PE51.11 70%Ni – 30 %PMMA 121.3070%NiZn – 30 %PE75.02 60%Co – 40 %PMMA 64.9080%NiZn – 20 %PE72.56 70%Co – 30 %PMMA 108.5290%NiZn – 10 %PE29.29 60%NiZn – 40 %PMMA 207.57 90%NiZn – 10 %UHMWPE 300 83.40 70%NiZn – 30 %PMMA 342.36 90%NiZn – 10 %UHMWPE 500 102.13

20. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 20 Mechanical and Strength Properties Testing Radial Crushing Strength Measurement Typical photos of the radial crushing strength measurement results

21. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 21 10%PE – 90%NiZn(50:20:30) (1300 o C, 950 minutes) ( yellow curve: Inductance; Blue curve: Resistance) without surface coating Magnetic Properties Testing by HP4149A Analyzer Performance Comparison for Different materials

22. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 22 10%PE – 90%NiZn(50:30:20) (1300C, 950 minutes) ( yellow curve: Inductance; Blue curve: Resistance) Performance Comparison for Different materials Magnetic Properties Testing by HP4149A Analyzer

23. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 23 10%PE – 90%NiZn(50:40:10) (1300 oC, 950 minutes) ( yellow curve: Inductance; Blue curve: Resistance) Performance Comparison for Different materials Magnetic Properties Testing by HP4149A Analyzer

24. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 24 10%PE – 90%NiZn(50:20:30) (1100 o C, 20 hours)( yellow curve: Inductance; Blue curve: Resistance) Performance Comparison for Different materials Magnetic Properties Testing by HP4149A Analyzer

25. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 25 Magnetic Measurement Results (Loop Number N = 45) 5 kHz50 kHz100 kHz500 kHz 1 MHz 2 MHz 10 MHz 10%PE 90%NiZn(50:20:30 mol) (1100 o C, 20 hours) L (μH)43.9842.5542.4042.0341.9842.2955.54 μ r (new)33.1232.0431.9331.6531.6131.8441.82 10%PE 90%NiZn(50:20:30 mol) (1300 o C, 950 minutes) L (μH)56.0055.4555.2654.8655.0155.5980.58 μ r (new)42.1741.7541.6141.3141.4241.8660.68 10%PE 90%NiZn(50:30:20 mol) (1300 o C, 950 minutes) L (μH)50.4949.3849.2748.9849.0649.7777.51 μ r (new)38.0237.1837.1036.8831.1937.4858.37 10%PE 90%NiZn(50:40:10 mol) (1300 o C, 950 minutes) L (μH)38.3037.9437.8437.5337.4737.6148.86 μ r (new)28.9428.5728.4928.2628.2128.3236.79 Performance Comparison for Different materials Magnetic Properties Testing by HP4149A Analyzer

26. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 26 B-H loop test circuit Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

27. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 27 Material 1: 10%PE – 90%NiZn(50:30:20), (1300 o C, 950 minutes) μr = 62.56 (Y:3.4×10 -2 Tesla/Div, X:431.8182A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

28. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 28 Material 2: 40%PMMA-60%NiZn(1300C), μr = 19.06 (Y:3.32×10 -2 Tesla/Div, X:1386.364A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

29. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 29 Material 3: 30%PMMA-70%Ni, μr = 17.89 (Y:3.32×10 -2 Tesla/Div, X:1447.273A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

30. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 30 Material 4: 30%PMMA-70%MnZn(1300 o C), μr = 17.21 (Y:2.38×10 -2 Tesla/Div, X:1102.273A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

31. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 31 Material 5: 40%PMMA -60%Ni, μr = 12.69 (Y:2.36×10 -2 Tesla/Div, X:1477.273A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

32. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 32 Material 6: 30%PMMA-70%MnZn(1300 o C), μr = 13.15 (Y:2.33×10 -2 Tesla/Div, X:1409.091A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

33. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 33 Material 7: 40%PMMA-60% NiZn (900 o C), μr = 12.74 (Y:2.33×10 -2 Tesla/Div, X:1454.545A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

34. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 34 Material 8 : 40%PMMA-60% NiZn (1100 o C), μr = 15.27 (Y:2.36×10 -2 Tesla/Div, X:1227.273A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

35. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 35 Material 1: 10%PE – 90%NiZn(50:30:20), (1300 o C, 950 minutes) μr = 62.56 (the Best) (Y:3.4×10 -2 Tesla/Div, X:431.8182A/m/Div) Magnetic Properties Testing by B-H Loop Test Circuit Performance Comparison for Different materials

36. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by EI40 core magnetic model for the power converter applications(2D) Magnetic Model for EI40 Polymer Core By MEGA6.29

37. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by EI40 core magnetic model for the power converter applications(3D) Magnetic Model for EI40 Polymer Core By MEGA6.29

38. THE HONG KONG POLYTECHNIC UNIVERSITY 香港理工大學 EE PERC π S upported by 38 Thank you