Fe-Based Nanocrystal Coil Component for Magnetic Permeability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in miniaturizing and thinning coil components for electronic devices is maintaining their magnetic characteristics, as increasing the magnetic material ratio is limited by changes in inductor strength and frequency characteristics, and controlling nanocrystal grain sizes of Fe-based metal powder particles is difficult, especially when using Fe-based metal powder particles in a powder form.
Innovation Solution
A coil component utilizing an Fe-based nanocrystal grain alloy in a powder form with specific composition and size ranges, exhibiting one or two peaks in differential scanning calorimetry graphs, where the primary peak is smaller than the secondary peak, and nanocrystal grains are within 20 nm to 50 nm in size, enhancing magnetic permeability and DC bias characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the ratio of magnetic material in the core is increased to maintain magnetic characteristics during miniaturization, then magnetic permeability is improved, but the strength of the inductor body deteriorates
Solution Approach 1:
The patent changes the physical and chemical parameters of the magnetic material by using Fe-based alloy particles with specific composition (Fe-Si-B-Nb-Cu system) and controlled particle size distribution (0.5-5 μm). This allows achieving high magnetic permeability with reduced material density, thus maintaining magnetic characteristics while preserving mechanical strength.
Solution Approach 2:
The patent employs composite material structure by combining Fe-based alloy particles with binder materials to form a core with optimized magnetic properties. The composite structure allows dispersing magnetic particles throughout the binder matrix, achieving high magnetic permeability without excessive material concentration that would compromise structural integrity.
2Stability of the object's composition
If Fe-based metal powder particles are used instead of ferrite, then magnetic permeability and saturation magnetic flux density are improved, but control over nanocrystal grain sizes becomes difficult
Solution Approach 1:
The patent applies preliminary action by pre-forming the Fe-based alloy particles with controlled size distribution (0.5-5 μm) and specific composition before incorporating them into the core. The particles are prepared in advance with optimized crystalline structure and size, eliminating the need for post-processing nanocrystal grain control and ensuring consistent magnetic properties.
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 Fe-based nanocrystal grain alloy improves magnetic permeability and DC bias characteristics, allowing for stable and efficient performance in coil components, as demonstrated by thermal analysis and experimental results showing enhanced inductance and efficiency compared to comparative examples.
Implementation Method 1
the Fe-based nanocrystal grain alloy has one peak or two peaks in a differential scanning calorimetry (DSC) graph
Data Source
AI summary
A coil component includes a body in which a coil portion is disposed, and external electrodes connected to the coil portion. The body includes metal particles formed of an Fe-based nanocrystal grain alloy, and the Fe-based nanocrystal grain alloy has one peak or two peaks in a differential scanning calorimetry (DSC) graph, and when the Fe-based nanocrystal grain alloy has the two peaks, a primary peak is smaller than a secondary peak, where the primary peak is at a lower temperature than the secondary peak.