Core-shell magnetic material oxidation resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-frequency magnetic materials face challenges in maintaining excellent characteristics in the GHz band and achieving high environmental resistance, particularly in suppressing oxidation of metallic fine particles in core-shell magnetic materials.
Innovation Solution
A core-shell magnetic material is developed, where magnetic metallic particles are coated with an oxide, nitride, or carbide layer, and bound by a binder made of specific resins with different oxygen permeability and water absorption properties, along with the inclusion of oxide, nitride, or carbide particles between the magnetic metallic particles, to enhance oxidation resistance and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a core-shell magnetic material uses a metallic fine particle covered with a single inorganic material layer, then the high-frequency characteristics can be improved, but the oxidation resistance of the metallic particle is insufficient
Solution Approach 1:
The patent divides the protective coating into multiple independent layers: an inner layer made of first inorganic material and an outer layer made of second inorganic material. This segmentation allows each layer to perform specific functions - the inner layer provides primary oxidation protection while the outer layer enhances environmental resistance, collectively solving the oxidation resistance problem without excessive complexity
Solution Approach 2:
The patent employs a composite coating structure combining different inorganic materials (first inorganic material and second inorganic material) with distinct properties. This composite approach creates a synergistic effect where the combination of materials provides superior oxidation resistance and environmental stability compared to a single material layer, addressing the reliability concern
2Reliability
If the oxygen permeability of the binder resin is high, then the ease of manufacture is improved, but the oxidation of the magnetic metallic particle increases
Solution Approach 1:
The patent uses a coating layer made of inorganic materials that forms a dense, low-permeability barrier film around the magnetic metallic particle. This thin film structure effectively blocks oxygen diffusion while maintaining a manageable manufacturing process, balancing oxidation suppression with ease of manufacture
Solution Approach 2:
The patent creates an inert protective environment around the magnetic metallic particle by using inorganic coating materials with low oxygen permeability. This inert barrier prevents oxygen from reaching the metallic particle, suppressing oxidation without requiring complex manufacturing conditions or special resin formulations
3Reliability
If the water absorption percentage of the binder resin is high, then the ease of manufacture is improved, but the environmental resistance and characteristic stability deteriorate
Solution Approach 1:
The patent employs an outer coating layer that forms a protective barrier with low water absorption properties. This barrier film prevents moisture from penetrating to the binder resin, allowing the use of resins with better processing characteristics while maintaining high environmental resistance and characteristic stability
Solution Approach 2:
The patent uses a composite coating structure where the outer layer material is selected for its low water absorption properties. This composite approach allows the binder resin to have optimal manufacturing characteristics while the outer coating layer compensates by providing the necessary environmental resistance, achieving both ease of manufacture and characteristic stability
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 provides a core-shell magnetic material with improved high-frequency characteristics and environmental resistance, effectively preventing oxidation and maintaining performance in harsh environments.
Implementation Method 1
the covering layer is made of an oxide, a nitride, or a carbide that contains at least one magnetic metal that contained in the magnetic metallic particle
Implementation Method 2
an oxygen permeability coefficient of the second resin is lower than an oxygen permeability coefficient of the first resin
Data Source
AI summary
A core-shell magnetic material having an excellent characteristic in a high-frequency band, in particular a GHz-band and a high environment resistance is provided. The core-shell magnetic material includes: a magnetic member in which plural core-shell magnetic particles are bound by a binder made of a first resin; and a coating layer that is made of a second resin different from the first resin, a surface of the magnetic member being covered with the coating layer. The core-shell magnetic material is characterized in that the core-shell magnetic particle includes a magnetic metallic particle and a covering layer that covers at least part of a surface of the magnetic metallic particle, the magnetic metallic particle contains at least one magnetic metal selected from a group consisting of Fe, Co, and Ni, and the covering layer is made of an oxide, a nitride, or a carbide that contains at least one magnetic metal.