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Inductors and transformers (here referred to as power components) for modern AC/DC switching power supplies require magnetic materials that have high power density and efficiency at high frequencies, with high magnetic saturation, low coercivity, and multi‐micrometer thicknesses to increase magnetic energy storage and power handling. Rather than using a single‐phase magnetic material in a polymer‐based composite, a composite formed from two magnetic phases (such as a 0‐3 nanocomposite) can simultaneously achieve all of the listed requirements and benefit from contributions by both the zero‐ and three‐dimensional phases to the magnetic properties. The fabrication of 0‐3 magnetic nanocomposites for power component applications requires a method to deposit magnetic nanoparticles into thick, physically stable yet porous films, and a subsequent method for infiltrating the magnetic nanoparticle film with another magnetic material. Here, the deposition of magnetic nanoparticles into micron‐thick films using electrophoretic deposition (EPD) is discussed. This is described along with a new method, to improve upon traditional EPD methods by increasing film–substrate interactions with chelating agents, therefore increasing film stability. Next, the use of electro‐infiltration for fully incorporating a secondary magnetic material within the nanoparticle film is presented, showing the cumulative fabrication process with the addition of a multilayered nanocomposite fabrication technique for increasing overall nanocomposite thickness. The subsequent cross‐sectional and magnetic characterization of the fabricated 0‐3 nanocomposites is also shown. Finally, future directions for 0‐3 magnetic nanocomposites are offered, with emphasis on potential materials synthesis techniques and on translating knowledge beyond power component applications.

 

Incorporating nanoparticles into devices for a wide range of applications often requires the formation of thick films, which is particularly necessary for improving magnetic power storage, microwave properties, and sensor performance. One approach to assembling nanoparticles into films is the use of electrophoretic deposition (EPD). This work seeks to develop methods to increase film thickness and stability in EPD by increasing film-substrate interactions via functionalizing conductive substrates with various chelating agents. Here, we deposited iron oxide nanoparticles onto conductive substrates functionalized with three chelating agents with different functional moieties and differing chelating strengths. We show that increasing chelating strength can increase film-substrate interactions, resulting in thicker films when compared to traditional EPD. Results will also be presented on how the chelating strength relates to film formation as a function of deposition conditions. Yield for EPD is influenced by deposition conditions including applied electric field, particle concentration, and deposition time. This work shows that the functionalization of substrates with chelating agents that coordinate strongly with nanoparticles (phosphonic acid and dopamine) overcome parameters that traditionally hinder the deposition of thicker and more stable films, such as applied electric field and high particle concentration. We show that functionalizing substrates with chelating agents is a promising method to fabricate thick, stable films of nanoparticles deposited via EPD over a larger processing space by increasing film-substrate interactions.