Co-Fired Spinel Oxide Assembly for Glue-Free Ferrite Composites
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Solution Overview
Problem
The conventional process for making composite magnetic-dielectric disc assemblies is inefficient due to the need for machining, adhesive application, and curing, which complicates the assembly and increases processing time.
Innovation Solution
A method involving the co-firing of pre-sintered magnetic articles with green articles containing precursor oxides at a temperature between 1300°C and 1450°C, forming a non-magnetic spinel-structured oxide without the need for adhesives, allowing for a glue-free assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional machining and adhesive application processes are used to assemble magnetic-dielectric disc assemblies, then adhesion between components is achieved, but processing time and manufacturing complexity increase
Solution Approach 1:
The patent combines the magnetic ceramic material and dielectric ceramic material into a single co-fired composite component. By integrating both materials during the sintering process, the need for separate machining and adhesive application steps is eliminated, directly resolving the contradiction between achieving adhesion and reducing processing time
Solution Approach 2:
The invention extracts and eliminates the adhesive layer from the assembly process. By designing a co-fired composite where the magnetic and dielectric materials are directly bonded through the sintering process, the harmful factor of adhesive complexity and curing time is removed entirely
2Reliability
If machining is performed on the cylinder to promote adhesion, then adhesion between rod and cylinder is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges the magnetic rod and dielectric cylinder into a single co-fired composite component with integrated geometry. The external and internal surfaces are formed during the sintering process itself, eliminating the need for separate machining operations to create adhesion-promoting features
Solution Approach 2:
The invention segments the manufacturing process into: (1) forming green compacts of magnetic and dielectric materials separately, (2) assembling them in the desired configuration, and (3) co-sintering them into a single integrated component. This segmentation allows complex geometries to be achieved without complex machining steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the assembly process by eliminating the need for adhesives and machining for adhesion, resulting in a more efficient and cost-effective method for producing composite magnetic-dielectric disc assemblies.
Implementation Method 1
firing the green article and the pre-sintered magnetic article together to a temperature between 1300°C and 1450°C
Data Source
AI summary
The disclosed technology generally relates dielectric materials and methods of forming the same, and more particularly to a combination of co-fireable dielectric materials that can be attached to each other without the use of adhesives. In an aspect, a composite article comprises a magnetic portion comprising a nickel zinc ferrite. The composite article additionally comprises a non-magnetic portion contacting the magnetic portion, the non-magnetic portion comprising a spinel-structured oxide comprising Mg2-xAl2xTi1-xO4 and having a dielectric constant between about 7 and 14, wherein 0<x≤1.