Fe-Si-M Alloy Coil Component with Oxide Film Insulation
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Solution Overview
Problem
Existing coil components with ferrite magnetic materials face limitations in achieving sufficient magnetic permeability, high-temperature resistance, and reliability due to low insulation properties, which are exacerbated by the need for low-temperature heat treatment and insufficient resin densification.
Innovation Solution
A magnetic material composed of Fe—Si-M soft magnetic alloy grains with an oxide film, where adjacent grains are bonded via the oxide film and directly in some areas, and resin is filled in voids to enhance insulation and permeability, using specific resin materials like silicone or epoxy to improve reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ferrite magnetic material is used in coil components, then insulation property is maintained, but magnetic permeability is insufficient
Solution Approach 1:
The patent uses a composite structure combining Fe-Si-M soft magnetic alloy grains with oxide film and resin material. The Fe-Si-M alloy provides high magnetic permeability, the oxide film provides insulation between grains, and the resin fills voids to enhance overall insulation and mechanical strength. This composite approach resolves the contradiction by integrating materials with complementary properties.
2Stability of the object's composition
If low-temperature heat treatment is performed to keep resin integrity, then resin structure is preserved, but Ag electrode density is insufficient
Solution Approach 1:
The patent separates the heat treatment process into two distinct stages: first, low-temperature heat treatment to sinter the Ag electrode and form the oxide film; second, high-temperature heat treatment after resin impregnation to densify the Ag electrode further without compromising the resin. This extraction of the heat treatment process into separate stages resolves the contradiction between resin integrity and Ag electrode density.
3Reliability
If metal powder and resin composite structure is adopted to ensure insulation, then insulation property is improved, but magnetic permeability is insufficient
Solution Approach 1:
The patent applies local quality by forming oxide film specifically on the surface of each Fe-Si-M alloy grain. This oxide film provides localized insulation at the grain boundaries while the bulk Fe-Si-M alloy grains maintain high magnetic permeability. The resin material is selectively placed in the voids between grains to provide additional insulation without interfering with the magnetic properties of the alloy grains.
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 magnetic material with improved magnetic permeability, high insulation resistance, and enhanced reliability, including moisture resistance and high-temperature performance, by optimizing grain bonding and resin filling.
Implementation Method 1
oxide film formed on the surface of the metal grains... bonding parts where adjacent metal grains are bonded together via the oxide film
Implementation Method 2
multiple metal grains constituted by Fe—Si-M soft magnetic alloy... improved magnetic permeability
Data Source
AI summary
An object is to provide a magnetic material and coil component offering improved magnetic permeability and insulation resistance, while also offering improved high-temperature load, moisture resistance, water absorbency, and other reliability characteristics at the same time. A magnetic material that has multiple metal grains constituted by Fe—Si-M soft magnetic alloy (where M is a metal element that oxidizes more easily than Fe), as well as oxide film constituted by an oxide of the soft magnetic alloy and formed on the surface of the metal grains, wherein the magnetic material has bonding parts where adjacent metal grains are bonded together via the oxide film formed on their surface, as well as bonding parts where metal grains are directly bonded together in areas having no oxide film, and resin material is filled in at least some of the voids generating as a result of accumulation of the metal grains.