Ni-Zn Ferrite Sintered Body Composition for Thermal Shock Resistance
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Solution Overview
Problem
Ferrite sintered bodies used in wire-wound coil components often lack sufficient heat resistance and thermal shock resistance, leading to compromised performance in high-frequency noise removal.
Innovation Solution
A ferrite sintered body composition comprising 45.0% to 49.7% Fe2O3, 2.0% to 8.0% CuO, 25.0% to 45.0% NiO, and 1.0% to 20.0% ZnO, with 5 ppm to 25 ppm B and 6 ppm to 25 ppm Nb, and optionally 100 ppm or less Mo, is developed, enhancing flexural strength and cross-point frequency for improved thermal shock resistance and noise absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ferrite materials (Ni-Zn or Mn-Zn based) are used for the drum core, then the manufacturing process is simple and cost-effective, but the thermal shock resistance is insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the ferrite material by adding specific amounts of CuO (2-8 mol%), B (5-25 ppm), and Nb (6-25 ppm) to the conventional Ni-Zn ferrite system. This compositional parameter adjustment improves thermal shock resistance while maintaining manufacturing feasibility through standard sintering processes.
Solution Approach 2:
The patent creates a composite ferrite material by combining multiple oxide components (Fe2O3, CuO, NiO, ZnO, B, Nb) in specific proportions. This composite approach leverages the synergistic effects of different materials to achieve superior thermal shock resistance compared to conventional single-phase ferrites.
2Strength
If ferrite material with insufficient heat resistance is used, then the manufacturing cost is lower, but the flexural strength after thermal shock deteriorates
Solution Approach 1:
The patent optimizes the chemical composition parameters within specific ranges: Fe2O3 (45.0-49.7 mol%), CuO (2.0-8.0 mol%), NiO (25.0-45.0 mol%), ZnO (1.0-20.0 mol%), B (5-25 ppm), and Nb (6-25 ppm). These parameter changes enhance both heat resistance and flexural strength after thermal shock simultaneously.
3Reliability
If the cross-point frequency is low, then the manufacturing is easier, but the high-frequency noise removal efficiency is reduced
Solution Approach 1:
The patent adjusts the compositional parameters, particularly the ZnO content (1.0-20.0 mol%) and the ratio of NiO to ZnO, to shift the cross-point frequency to higher values. This enables efficient high-frequency noise removal while maintaining manufacturing precision through controlled sintering processes.
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 ferrite sintered body exhibits high flexural strength after thermal shock and increased cross-point frequency, effectively addressing heat resistance and noise absorption issues, making it suitable for high-temperature applications like automotive components.
Implementation Method 1
the cross-point frequency, at which the reactance X is equal to the resistance R, is also desired to be high from the viewpoint of efficiently removing high-frequency noise components
Data Source
AI summary
A ferrite sintered body contains from 45.0% by mole to 49.7% by mole Fe in terms of from Fe2O3, 2.0% by mole to 8.0% by mole Cu in terms of CuO, from 25.0% by mole to 45.0% by mole Ni in terms of NiO, and from 1.0% by mole to 20.0% by mole Zn in terms of ZnO, in which when Fe, Cu, Ni, and Zn are converted to Fe2O3, CuO, NiO, and ZnO, respectively, and when the total amount of the Fe2O3, the CuO, the NiO, and the ZnO is 100 parts by weight, the ferrite sintered body contains from 5 ppm to 25 ppm B in terms of elemental B and from 6 ppm to 25 ppm Nb in terms of elemental Nb.