Ferrite Composition for Multilayer Inductor Noise Removal
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Solution Overview
Problem
Multilayer ferrite inductors face challenges in achieving noise removal characteristics comparable to winding-wire type ferrite inductors, especially with increasing AC currents in ICT equipment, necessitating improved ferrite compositions for enhanced inductance, resistivity, and permeability.
Innovation Solution
A ferrite composition comprising 10.0 to 38.0 mol % Fe2O3, 3.0 to 11.0 mol % CuO, 39.0 to 80.0 mol % ZnO, with a balance of NiO, and including 10.0 to 23.0 parts by weight of SiO2, 0 to 3.0 parts by weight of Co3O4, and 0.1 to 3.0 parts by weight of Bi2O3, forming a spinel ferrite with Zn2SiO4 and SiO2 phases for improved inductance and noise removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multilayer ferrite inductors use conventional ferrite compositions, then manufacturing complexity is reduced compared to winding-wire type, but noise removal characteristics are insufficient for large current applications
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of multiple oxides (Fe2O3: 10-38 mol%, CuO: 3-11 mol%, ZnO: 39-80 mol%, NiO: balance) and adding specific amounts of SiO2 (10-23 parts by weight), Co3O4 (0-3.0 parts by weight), and Bi2O3 (0.1-3.0 parts by weight) to achieve optimal magnetic properties for noise removal while maintaining multilayer structure simplicity
Solution Approach 2:
The patent uses composite materials by creating a multi-phase ferrite system containing spinel ferrite main phase, Zn2SiO4 sub-phase, and SiO2 grain boundary phase, combining multiple oxide components to achieve superior noise removal characteristics that match or exceed winding-wire type inductors
2Reliability
If ferrite composition is optimized for high permeability, then inductance characteristics improve, but resistivity may decrease leading to higher AC resistance
Solution Approach 1:
The patent optimizes the balance between permeability and resistivity by controlling Fe2O3 content (10-38 mol%) which affects magnetic moment and permeability, while simultaneously adjusting ZnO (39-80 mol%) and SiO2 (10-23 parts by weight) content to maintain high resistivity and reduce AC resistance through grain boundary effects
Solution Approach 2:
The patent creates a composite structure with spinel ferrite main phase providing high permeability for good inductance characteristics, while SiO2 grain boundary phase and Zn2SiO4 sub-phase provide high resistivity pathways that reduce eddy current losses and AC resistance, achieving both high inductance and low energy loss
Data Source
AI summary
A ferrite composition includes a main component and a sub-component. The main component includes 10.0 to 38.0 mol % of a Fe compound in terms of Fe2O3, 3.0 to 11.0 mol % of a Cu compound in terms of CuO, 39.0 to 80.0 mol % (excluding 39.0 mol %) of a Zn compound in terms of ZnO, and a balance of a Ni compound. The sub-component includes 10.0 to 23.0 parts by weight of a Si compound in terms of SiO2, 0 to 3.0 parts by weight (including 0 parts by weight) of a Co compound in terms of Co3O4, and 0.1 to 3.0 parts by weight of a Bi compound in terms of Bi2O3 with respect to 100 parts by weight of the main component.