High frequency low loss magnetic core and method of manufacture

A method for forming a low loss, high magnetic saturation magnetic material having a saturation magnetization above 1.5 T and a power density of less than 2000 kW/m3 at frequencies above 5 KHz, said method comprising:

• A. providing a plurality of magnetic particles having an average particle size of 20-1500 μm and having a saturation magnetization above 1.5 T;
• said magnetic particles structured and engineered to have low coercivity of less than <10 Oersted;
• said magnetic particles include one or more materials selected from the group consisting of iron, iron-silicon, glassy iron, iron-nickel, iron-silicon, iron-cobalt-vanadium, NiTi, orthinol, silicon steel, and iron-cobalt alloy;
• B. coating said magnetic particles with a coating;
• said coating having a melting point above 350° C.;
• said coating having a thickness of 5-200 nm;
• said coating including one of more of I) polymer that includes one or more materials selected from the group consisting of polyether ether ketone, polyimide, polyphenyl sulfone, polysiloxane, silicone, polysilizane, phenolic, II) inorganic material that includes one or more materials selected from the group consisting of silica, silicate, silicate glass, BN, BN nanosheets, AlN, Si3N4, TiO2, titanate, MgO, Al2O3, SiOC, SiAlON, aluminate, aluminosilicate, mica, B2O3, borosilicate, borate glass, Fe3O4, (Mn(Fe2O4), and Zn(Fe2O4), and III) metal material including one or more materials selected from the group consisting of iron, ferrite, silicon metal, germanium metal, carbon, boron, arsenide, and selenide;
• and
• C. consolidating said coated magnetic particles by a sintering process using heating and pressure to form said low loss, high magnetic saturation magnetic material;
• said low loss, high magnetic saturation magnetic material having a density that is greater than 90% of a theoretical density of said magnetic particles used to form said low loss, high magnetic saturation magnetic material.