Metallurgical advancements in soft magnetic materials are paving the way for significant improvements in wireless charging technology. When compared to traditional wired charging methods, wireless charging results in more energy loss and heat generation during the charging process. This inefficiency limits charging speed but also poses potential thermal management challenges for devices and batteries. Moreover, the distance limitations of effective wireless charging mean that devices must be placed very close to the charging pad, often requiring precise alignment for optimal performance.
At Xtalic, we have continued to invest in research and development around soft magnetic materials—specifically, alloys that are easily magnetized and demagnetized based on the magnetic field they are in. One of our recent breakthroughs is XENERGY (pronounced: ZEN-ur-gee), a patent-pending nanostructured soft magnetic nickel-iron-cobalt alloy.
The primary application interests for XENERGY are inductive wireless charging applications. Specifically, these alloys show the greatest performance gain and value when used in space constrained applications, like inside a consumer electronic device. The value is further compounded when the application frequency is high, accelerating the impact of the soft magnetic materials. Thus, use cases in the Qi, Qi2 and NFC bands are particularly impacted.
As we delved deeper into the alloy and application potential, we began to explore adjacent technology spaces. The unique properties of XENERGY make it a versatile solution for many high-performance applications.
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Expanding Production Capabilities of Soft Magnetic Materials
In wireless charging applications, soft magnetic materials like XENERGY have shown remarkable results. We apply a thin layer (~1 μm or less) of XENERGY onto very fine gauge copper wire. By engineering the surface functionality of the wire with a soft magnetic materials, we see a substantial boost in the measured inductance, a reduction in AC resistance, and an overall increase (50%+) in the Q value of the inductive coils. For users, this translates to faster charging times with less heat buildup, enhancing the efficiency and performance of wireless charging systems.
To meet growing customer demand, we have expanded our internal sampling capability with a second reel-to-reel wire plating line at our R&D labs in Marlborough. These lines enable the production of metallic-coated wires with precise engineering control over wire tension and spooling. Xtalic has successfully produced coatings on wires as small as 25 μm and as large as 350 μm. Additionally, we have a manufacturing partner for dielectric coating and sealing, ensuring comprehensive production capabilities.
As part of our commercialization efforts, we have installed the XENERGY coating process on a serial production line with one of our partners in China, where fully coated and sealed wire can be produced. This allows us to produce samples of meaningful length so that customers can produce their own coils, Litz wire, and samples to qualify the materials and coatings in the final product form. To date, more than 250,000 km of wire has been produced—enough to stretch to the moon.
More on XENERGY
Discovering New Markets and Applications
Once we commercialize a new advanced material, it often finds applications beyond its initial purpose. For example, our nanostructured nickel alloy, XTRONIC®, was designed for high-speed network backplane connectors but later found use in protecting waterproof smartphone USB-C connectors and cables. Similarly, we are looking at applications for XENERGY in passive components, like inductors and antennas.
We have developed a variation of the XENERGY product for advanced semiconductor applications, such as Integrated Voltage Regulators (IVRs). By starting with our established XENERGY alloy, our goal was to significantly increase its electrical resistivity. In high-frequency applications, such as voltage regulator modules, there is a need to block and reduce eddy current formation. A magnetic inductor, enhanced with a highly resistive soft magnetic coating, greatly reduces eddy current formation, thereby reducing losses and boosting efficiency. Using the Xtalic alloy design toolkit, we quickly identified and implemented alloying additions to XENERGY that increase electrical resistivity by reducing the electron mean free path.
Leveraging the Xtalic Toolkit for Future Innovations
The Xtalic toolkit continues to prove invaluable in developing and creating new and unique alloys to solve critical materials problems. XENERGY is the newest addition to our suite of nanostructured metal alloys, leveraging the unique advantages of soft magnetic materials at the atomic level to optimize properties and performance.
By utilizing XENERGY, system engineers can unlock new levels of product performance and features while maintaining safety, cost, and environmental goals. Our advanced materials solutions are helping to shape the future of technology, one application at a time.
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