Ferrite Composition for Multilayer Inductors
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Solution Overview
Problem
Current ferrite compositions and multilayer electronic components do not meet the requirements for high inductance properties, resistivity, and noise removal capabilities, especially in high current environments, where winding type ferrite inductors excel but multilayer type ferrite inductors fall short.
Innovation Solution
A ferrite composition with a specific range of Fe, Cu, Zn, Ni, Si, Co, and Bi compounds, along with a spinel ferrite main phase, Zn2SiO4 subphase, and SiO2 grain boundary phase, optimized to enhance inductance, resistivity, and DC bias properties, achieving noise removal performance comparable to or exceeding that of winding type ferrite inductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multilayer type ferrite inductors use conventional ferrite compositions, then manufacturing simplicity and compact structure are achieved, but noise removal properties and inductance characteristics are insufficient compared to winding type ferrite inductors
Solution Approach 1:
The patent applies parameter changes by precisely controlling the compositional ratios of multiple metal oxides in the ferrite material. Specifically, it optimizes Fe2O3 content to 44-50 mol%, CuO to 5.5-14 mol%, ZnO to 4-39 mol%, and NiO to less than 40 mol%, while also controlling subcomponent ratios such as Co3O4/SiO2 weight ratio of 0.4-2.9. These parameter optimizations enable multilayer ferrite inductors to achieve noise removal properties comparable to winding type inductors while maintaining the manufacturing simplicity of multilayer structures.
Solution Approach 2:
The patent employs composite materials by creating a multi-phase ferrite composition system consisting of a main spinel ferrite phase and subphases including Zn2SiO4 and SiO2. This composite structure combines different metal oxide compounds (Fe, Cu, Zn, Ni, Co, Si, Bi) to achieve synergistic effects that improve both inductance characteristics and noise removal properties, resolving the contradiction between performance enhancement and composition complexity.
2Reliability
If higher content of Co compound is added to improve DC bias properties, then DC bias performance improves, but the weight ratio relative to Si compound should be controlled within 0.4 to 2.9 to maintain overall balance
Solution Approach 1:
The patent applies parameter changes by precisely controlling the Co3O4 content and its weight ratio relative to SiO2 within the range of 0.4-2.9. This parameter optimization ensures that sufficient Co compound is present to improve DC bias properties while maintaining compositional balance and preventing excessive Co content that would destabilize the ferrite structure. The specific ratio control allows optimization of DC bias performance while preserving overall composition stability.
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 optimized ferrite composition improves inductance properties, resistivity, and AC resistance, enabling multilayer electronic components to match or surpass the noise removal capabilities of winding type ferrite inductors, while maintaining excellent DC bias properties and sinterability.
Implementation Method 1
a main phase including a spinel ferrite
Implementation Method 2
a grain boundary phase including an SiO2 phase
Data Source
AI summary
A ferrite composition includes a main component that includes more than 44.0 mol % to 50.0 mol % or less of an Fe compound, 5.5 to 14.0 mol % of a Cu compound, 4.0 to 39.0 mol % of a Zn compound, and a balance of less than 40.0 mol % of a Ni compound. The ferrite composition further includes a subcomponent that includes, with respect to 100 parts by weight of the main component, more than 3.0 parts by weight to 13.0 parts by weight or less of an Si compound, more than 2.0 parts by weight to 10.0 parts by weight or less of a Co compound, and 0.25 to 5.00 parts by weight of a Bi compound. A weight ratio of the content of the Co compound to the content of the Si compound is 0.4 to 2.9.