Core-Shell Metal Particle Aggregate for High-Frequency Magnetic Permeability
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Solution Overview
Problem
High-frequency magnetic materials face challenges in maintaining low energy loss and transmission loss in electronic components, particularly due to aggregation of metal fine particles used in electromagnetic wave absorbers and devices, which affects their performance.
Innovation Solution
The development of a metal-containing particle aggregate comprising core-shell particles with a magnetic metal core and an oxide or carbon-containing shell layer, designed to prevent aggregation and enhance high-frequency magnetic permeability, where the core-shell particles have a high aspect ratio and specific compositions of Fe, Co, Al, and Si to improve thermal stability and oxidation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal fine particles are used as magnetic materials, then high-frequency magnetic permeability is improved, but particle aggregation occurs leading to increased energy loss
Solution Approach 1:
An oxide layer is introduced as an intermediary substance between metal fine particles. This oxide layer prevents direct contact and aggregation between particles while maintaining the magnetic properties of the metal core, thereby reducing energy loss from aggregation while preserving high-frequency magnetic permeability
Solution Approach 2:
The invention creates a composite structure consisting of a metal core and an oxide shell. This composite particle structure combines the high magnetic permeability of metal particles with the aggregation-preventing properties of the oxide layer, achieving both improved magnetic performance and reduced energy loss
2Adaptability or versatility
If metal fine particles are mixed with binder to form composite member, then device application is enabled, but particle aggregation occurs during processing
Solution Approach 1:
The oxide layer serves as a mediator between the metal particles and the binder material. It provides a surface that is compatible with the binder while preventing particle-particle contact, enabling proper mixing and device fabrication while maintaining stable particle dispersion throughout the composite member
Solution Approach 2:
The oxide layer acts as a thin film coating on the metal particles that provides steric and electrostatic stabilization. This flexible protective shell prevents aggregation during processing while allowing the particles to be uniformly distributed in the binder matrix
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 effectively prevents particle aggregation, enhances high-frequency magnetic permeability, and improves thermal stability and oxidation resistance, leading to improved performance in high-frequency applications by maintaining low energy loss and transmission loss in electronic components.
Implementation Method 1
a shell layer that includes an oxide layer that covers at least part of the core portion
Data Source
AI summary
A metal-containing particle aggregate of an embodiment of the present invention includes a plurality of core-shell particles. Each of the core-shell particles includes: a core portion that contains at least one magnetic metal element selected from the first group consisting of Fe, Co, and Ni, and at least one metal element selected from the second group consisting of Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, rare-earth elements, Ba, and Sr; and a shell layer that includes a carbon-containing material layer and an oxide layer that covers at least part of the core portion and includes at least one metal element that belongs to the second group and is contained in the core portion.