Ferrite Ceramic Composition for Crack-Resistant Wire-Wound Coils
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Solution Overview
Problem
Ceramic cores made of ferrite materials are prone to chipping during barrel polishing and cracking during thermocompression bonding, and can experience plating elongation issues when terminal electrodes are formed, which affects the reliability and performance of wire-wound coil components.
Innovation Solution
A ceramic composition containing specific amounts of Fe, Cu, Zn, Ni, Mn, Nb, and V, with a spinel ferrite as the main component, is developed to reduce chipping, cracking, and plating elongation, while maintaining high specific electrical resistance, by controlling the composition and processing conditions such as firing temperature and grain size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ferrite material is used for the drum core, then thermal shock resistance is improved, but the core may chip in barrel polishing or crack in thermocompression bonding, and plating elongation may occur
Solution Approach 1:
The patent modifies the chemical composition parameters of the ferrite material by adding specific amounts of Nb (2-30 ppm) and V (10-60 ppm) to the existing Fe-Cu-Zn-Ni-Mn system. This parameter change in composition transforms the material properties to simultaneously achieve thermal shock resistance and reduced chipping/cracking during processing
Solution Approach 2:
The patent creates a composite ferrite material system by combining multiple metal oxides (Fe2O3, CuO, ZnO, NiO, Mn2O3, Nb2O5, V2O5) in specific proportions. This composite approach leverages the synergistic effects of different elements to achieve both thermal shock resistance and mechanical integrity during polishing and bonding operations
2Reliability
If terminal electrodes are formed on the bottom surfaces of the core by plating, then electrical connection is achieved, but plating elongation occurs causing displacement from intended position
Solution Approach 1:
The patent changes the substrate material parameters by incorporating Nb and V elements into the ferrite composition, which modifies the surface properties and thermal characteristics. This parameter change in the core material reduces plating elongation during electrode formation, improving manufacturing precision while maintaining electrical connection reliability
Data Source
AI summary
The ceramic composition contains Fe, Cu, Zn, Ni, Mn, Nb, and V. When the amounts of Fe, Cu, Zn, and Ni are respectively expressed in terms of Fe2O3, CuO, ZnO, and NiO, and a total amount of Fe2O3, CuO, ZnO, and NiO is 100 mol %, the ceramic composition contains from 46.70 mol % to 49.70 mol % of Fe in terms of Fe2O3, from 4.00 mol % to 7.50 mol % of Cu in terms of CuO, and from 7.00 mol % to 33.50 mol % of Zn in terms of ZnO, with the balance being Ni, and contains from 300 ppm to 10,000 ppm of Mn in terms of Mn2O3, from 2 ppm to 30 ppm of Nb in terms of Nb2O5, and from 10 ppm to 60 ppm of V in terms of V2O5 with respect to 100 parts by weight of the total amount of Fe2O3, CuO, ZnO, and NiO.