Soft Magnetic Alloy Coil Component via Oxide Layer Bonding
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Solution Overview
Problem
Existing coil-type electronic components face challenges in achieving high magnetic permeability and saturation magnetic flux density while maintaining low production costs, particularly due to the need for high-pressure compression molding and costly insulation treatments in metal magnetic materials.
Innovation Solution
A coil-type electronic component using soft magnetic alloy grains with an oxide layer formed through heat treatment in an oxidizing atmosphere, eliminating the need for resin or glass insulation and reducing production costs by bonding grains via the oxide layer, which enhances magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If metal magnetic materials are used to achieve high saturation magnetic flux density, then magnetic performance is improved, but insulation treatment is required which increases production cost
Solution Approach 1:
The metal magnetic alloy grains self-form an oxide layer on their surfaces through oxidation during sintering, which automatically provides electrical insulation between grains without requiring external insulation treatment. This self-service mechanism eliminates the need for additional insulation processes while maintaining high saturation magnetic flux density.
Solution Approach 2:
An oxide layer acts as an intermediary substance between metal magnetic alloy grains, providing electrical insulation while allowing the grains to maintain close contact for magnetic coupling. This intermediary layer resolves the contradiction by enabling both high magnetic performance and electrical insulation simultaneously.
2Reliability
If Fe-Al-Si powder with surface oxide film is used for compression molding, then insulation is achieved, but large molding force is required
Solution Approach 1:
Instead of pre-forming oxide films on powder surfaces before molding, the oxide layer is formed in advance during the sintering process after molding. This preliminary action during sintering eliminates the need for pre-oxidized powder and reduces molding force requirements while still achieving the necessary insulation property.
3Reliability
If glass coating is applied to metal magnetic grains for insulation, then insulation is improved, but production cost increases due to nitrogen atmosphere requirement
Solution Approach 1:
The invention replaces expensive glass coating with a simpler oxide layer that forms naturally during sintering in air atmosphere. This disposable-like approach uses readily available oxidation processes instead of costly controlled atmosphere sintering with glass materials, significantly reducing production cost while maintaining adequate insulation.
4Volume of stationary object
If high-pressure compression molding is used to densify magnetic material, then density is improved, but manufacturing complexity increases
Solution Approach 1:
The invention changes the sintering parameters (temperature, atmosphere, time) to achieve adequate density without requiring high-pressure compression molding. By optimizing sintering conditions, the material achieves sufficient densification through thermal processes alone, simplifying the manufacturing process while maintaining acceptable density levels.
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
The solution achieves high magnetic permeability and saturation magnetic flux density with reduced production costs and without the need for high-pressure molding or expensive insulation treatments, enabling smaller, more efficient electronic components.
Implementation Method 1
the molded product was heat-treated in an oxidizing atmosphere to break down the binder while an oxide layer was formed by oxidizing the surface of soft magnetic alloy grains
Implementation Method 2
soft magnetic alloy grains were bonded with one another, via the oxide layer, in this molded product that had been given heat treatment
Data Source
AI summary
A coil-type electronic component has a coil inside or on the surface of its base material and is characterized in that: the base material is constituted by a group of grains of a soft magnetic alloy containing iron, silicon and other element that oxidizes more easily than iron; the surface of each soft magnetic alloy grain has an oxide layer formed on its surface as a result of oxidization of the grain; this oxide layer contains the other element that oxidizes more easily than iron by a quantity larger than that in the soft magnetic alloy grain; and grains are bonded with one another via this oxide layer.