Investigation of the magnetic flux density dispersion Bd on the gaps of the FeSiBNbCu magnetically soft nanocrystalline block core

•Innovative technology utilizing the gaps with inserts of increased permeability.•Magnetic flux density dispersion phenomenon on the gaps in the multi-gap block core.•Multi-gap core with new inserts reduce the power losses and mass of the reactors. This paper focuses on the phenomenon of the magnetic flux density dispersion Bd on the gaps of the Fe73.5Cu1Nb3Si13.5B9 multi-gap nanocrystalline block core. Present state-of-the-art shows, that there is no comprehensive knowledge about the value of the magnetic flux density dispersion Bd on the gaps of nanocrystalline block core and the possibilities of its minimisation. The magnetic flux density dispersion Bd is the source of local eddy currents, which are the cause of increase of power loss and temperature in the chokes’ core. To discuss the effect of gap width and the method of its filling on the power losses in the core, the comparison between inserts of Teflon and magnetic mat composed of 70% Fe53.9Co29.1B13Nb1Si2Cu1 powder with a fraction of 20–36 µm and 30% Ultimeg epoxy resin 2004L was performed.