Composite Magnetic Material for GHz Components
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Solution Overview
Problem
Current magnetic materials face challenges in achieving high relative permeability and low magnetic loss in the GHz frequency band while maintaining adhesion and preventing cracking or peeling when used in electronic components.
Innovation Solution
A composite magnetic material comprising a powder with Fe or Fe and Co as the main component, having an average minor axis length of 100 nm or less, and a specific distribution of aspect ratios, combined with a resin, to enhance relative permeability and reduce magnetic loss, while ensuring strong adhesion and preventing cracking or peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the aspect ratio of magnetic material is increased to improve relative permeability and reduce magnetic loss in GHz band, then magnetic performance is improved, but adhesion deteriorates and cracking or peeling occurs when mounted
Solution Approach 1:
The patent changes the particle size parameter to an average minor axis length of 100 nm or less and controls the aspect ratio distribution within specific ranges (Av: 5-20, σ: 2-8). This parameter optimization allows achieving high relative permeability (μr≥1.5) and low magnetic loss (tanδ≤0.015) at 3.5 GHz while maintaining adhesion strength of 70% or more, resolving the contradiction between magnetic performance and adhesion.
Solution Approach 2:
The patent uses composite magnetic materials containing Fe or Fe-Co powders with controlled aspect ratios combined with resin matrices. The composite structure with specific powder morphology (average minor axis ≤100 nm, aspect ratio 5-20) and resin integration enables simultaneous achievement of high magnetic performance and strong adhesion, preventing cracking and peeling during mounting.
2Loss of energy
If the aspect ratio of magnetic material is increased to reduce magnetic loss in GHz band, then magnetic loss is reduced, but adhesion deteriorates and cracking or peeling occurs
Solution Approach 1:
The patent optimizes the aspect ratio distribution parameter (Av: 5-20, σ: 2-8) and particle size (average minor axis ≤100 nm) to achieve low magnetic loss (tanδ≤0.015) at 3.5 GHz while maintaining strong adhesion (70% or more). This parameter control resolves the contradiction between reducing magnetic loss and maintaining adhesion strength.
3Reliability
If smaller particle size is used to improve magnetic performance in GHz band, then relative permeability is improved, but manufacturing precision becomes more difficult to control
Solution Approach 1:
The patent specifies a particle size parameter of average minor axis length of 100 nm or less with controlled aspect ratio distribution (Av: 5-20, σ: 2-8). This precise parameter specification enables achieving high relative permeability (μr≥1.5) while maintaining manufacturing precision through defined particle morphology characteristics.
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 composite magnetic material achieves high relative permeability and low magnetic loss in the GHz frequency band, with excellent adhesion and resistance to cracking or peeling, thereby improving the performance and reliability of electronic components.
Implementation Method 1
a powder having a main component containing Fe or Fe and Co
Data Source
AI summary
A composite magnetic material includes a powder and a resin. The powder has a main component containing Fe or Fe and Co. An average minor axis length in primary particles of the powder is 100 nm or less. A point satisfying (X, Y)=(σ/Av (%), (Av-σ)) on an XY coordinate plane is present within a region (including a boundary) surrounded by three points α(24.5, 6.7), β(72.0, 1.2), and γ(24.5, 1.2), in which an average of aspect ratios in the primary particles of the powder is set to Av, and a standard deviation of the aspect ratios in the primary particles of the powder is set to σ.