Ferrite Core Composition for High Permeability and Low Core Loss
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Solution Overview
Problem
Ferrite cores with high magnetic permeability and low core loss are needed, but existing compositions that improve magnetic properties often compromise strength and formability due to increased grain boundaries.
Innovation Solution
A ferrite core composition with Mn, Zn, and Fe, along with specific additives like Co, Ni, SiO2, CaO, and Ta2O5, where these additives are distributed differently between grains and grain boundaries to enhance magnetic permeability and control grain growth, resulting in a core with high strength and formability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additives are used to improve magnetic properties of the ferrite core, then magnetic permeability increases, but grain boundaries between grains increase, which lowers strength and formability
Solution Approach 1:
The patent applies local quality by creating distinct compositional zones: grains enriched with Co and Ni for magnetic properties, and grain boundaries enriched with SiO2, CaO, and Ta2O5 for strength and controlled grain growth. This spatial differentiation of material properties resolves the contradiction by allowing each region to optimize its function locally.
Solution Approach 2:
The patent uses composite materials by combining multiple oxides (CoO, NiO, SiO2, CaO, Ta2O5) in specific proportions and distributions within the ferrite structure. The composite nature allows simultaneous achievement of high magnetic permeability through Co/Ni-rich grains and high strength through SiO2/CaO/Ta2O5-rich grain boundaries.
2Reliability
If grain boundaries are increased to improve magnetic properties, then magnetic permeability improves, but strength and formability are lowered
Solution Approach 1:
The patent creates local quality differences by concentrating SiO2, CaO, and Ta2O5 specifically at grain boundaries while keeping Co and Ni concentrated in grain interiors. This localized distribution allows grain boundaries to serve dual functions: maintaining electrical isolation for magnetic performance while providing structural reinforcement for strength.
Solution Approach 2:
The patent changes material parameters by controlling the concentration and distribution of five different oxide additives. By adjusting the content of CoO (1-10 wt%), NiO (1-5 wt%), SiO2 (0.1-5 wt%), CaO (0.1-5 wt%), and Ta2O5 (0.1-5 wt%), the patent optimizes both magnetic and mechanical properties simultaneously.
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 core achieves high magnetic permeability (3000 or more) and low core loss (800 or less), while maintaining strength and formability, making it suitable for various applications including vehicles and industrial uses.
Implementation Method 1
content of the Co and the Ni in the plurality of grains is two or more times higher than content of the Co and the Ni in the plurality of grain boundaries
Implementation Method 2
content of the SiO2, the CaO, and the Ta2O5 in the plurality of grain boundaries is two or more times higher than content of the SiO2, the CaO, and the Ta2O5 in the plurality of grains
Data Source
AI summary
A ferrite core according to an embodiment of the present invention includes a plurality of grains including Mn at 30 to 40 mol %, Zn at 5 to 15 mol %, and Fe at 50 to 60 mol %, and a plurality of grain boundaries disposed between the plurality of grains, wherein the plurality of grains and the plurality of grain boundaries include Co, Ni, SiO2, CaO, and Ta2O5, content of the Co and the Ni in the plurality of grains is two or more times higher than content of the Co and the Ni in the plurality of grain boundaries, content of the SiO2, the CaO, and the Ta2O5 in the plurality of grain boundaries is two or more times higher than content of the SiO2, the CaO, and the Ta2O5 in the plurality of grains, a magnetic permeability is 3000 or more, and a core loss is 800 or less.