Ferrite Sintered Body Composition for DC Bias and Sinterability
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Solution Overview
Problem
Existing ferrite sintered bodies and multilayer coil components face challenges in achieving good DC superposition characteristics and sinterability while minimizing plating elongation, which can degrade with increased zinc silicate content and bismuth oxide levels.
Innovation Solution
A ferrite sintered body composition with specific ranges of Fe, Zn, Cu, Ni, Si, Bi, and Zr, along with a multilayer coil component design featuring alternately stacked insulating layers and coil conductors, is developed to enhance DC superposition characteristics and sinterability while reducing plating elongation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zinc silicate content is increased to improve DC superposition characteristic, then magnetic permeability is improved, but sinterability is degraded
Solution Approach 1:
The patent applies parameter changes by precisely controlling the zinc silicate content within 8-76 wt% range and bismuth oxide within 0.025-0.231 wt% range, optimizing the balance between DC superposition characteristic and sinterability. This quantitative parameter optimization resolves the contradiction by finding the optimal composition window where both requirements are satisfied simultaneously.
Solution Approach 2:
The patent uses composite materials by combining zinc silicate with spinel ferrite and bismuth oxide in specific proportions. The composite magnetic material leverages the complementary properties of each component: zinc silicate provides DC superposition characteristic, spinel ferrite provides magnetic properties, and bismuth oxide enhances sinterability, thereby resolving the contradiction between individual material limitations.
2Ease of manufacture
If bismuth oxide content is increased to improve sinterability, then sinterability is improved, but plating elongation occurs degrading reliability
Solution Approach 1:
The patent applies parameter changes by precisely controlling the bismuth oxide content within 0.025-0.231 wt% range. This quantitative control optimizes sinterability while preventing excessive bismuth oxide that would cause plating elongation, thereby resolving the contradiction between manufacturing ease and product reliability.
3Reliability
If zinc silicate content is increased to improve DC superposition characteristic, then magnetic permeability is improved, but sinterability is degraded
Solution Approach 1:
The patent applies parameter changes by precisely controlling the zinc silicate content within 8-76 wt% range and bismuth oxide within 0.025-0.231 wt% range, optimizing the balance between DC superposition characteristic and sinterability. This quantitative parameter optimization resolves the contradiction by finding the optimal composition window where both requirements are satisfied simultaneously.
Solution Approach 2:
The patent uses composite materials by combining zinc silicate with spinel ferrite and bismuth oxide in specific proportions. The composite magnetic material leverages the complementary properties of each component: zinc silicate provides DC superposition characteristic, spinel ferrite provides magnetic properties, and bismuth oxide enhances sinterability, thereby resolving the contradiction between individual material limitations.
Data Source
AI summary
A ferrite sintered body contains a main component and a sub component. The main component contains from 4 mol % to 13 mol % of Fe in terms of Fe2O3, from 47 mol % to 58 mol % of Zn in terms of ZnO, from 1 mol % to 4 mol % of Cu in terms of CuO, from 2 mol % to 8 mol % of Ni in terms of NiO, and from 28 mol % to 36 mol % of Si in terms of SiO2. The sub component contains, per 100 parts by weight of the main component, from 0.8 parts by weight to 3 parts by weight of Bi in terms of Bi2O3 and from 0.005 parts by weight to 0.1 parts by weight of Zr in terms of ZrO2.