Sintered Magnetic Material Using Grain Boundary Oxides for High-Frequency Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Composite magnetic materials with a resin experience increased eddy current loss and degraded high-frequency characteristics due to localized magnetic flux concentration between soft magnetic powder particles.
Innovation Solution
A magnetic material comprising a sintered body of metal magnetic particles with a grain boundary phase made of a metal oxide or nitride, which increases electrical resistivity and reduces eddy current loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a composite magnetic material includes a resin with soft magnetic powder particles, then the magnetic material can be formed with flexible composition, but eddy current loss increases and high-frequency characteristics degrade due to localized magnetic flux concentration between particles
Solution Approach 1:
The patent applies local quality by creating a non-uniform grain boundary phase distribution at specific locations (grain boundaries between metal magnetic particles) rather than uniform distribution throughout the material. The grain boundary phase contains metal oxide or metal nitride with higher electrical resistivity, locally modifying the electrical properties at particle interfaces to suppress eddy current paths while maintaining the overall composite structure and flexible composition capabilities
Solution Approach 2:
The patent uses composite materials by combining metal magnetic particles with a grain boundary phase consisting of metal oxide or metal nitride. This composite structure at the grain boundary level creates a multi-phase material where the oxide/nitride phase provides electrical isolation between magnetic particles, reducing eddy current loss while preserving the magnetic properties of the metal particles
2Loss of energy
If the grain boundary phase contains metal oxide or metal nitride of nonmagnetic metal, then electrical resistivity increases and eddy current loss decreases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-forming the grain boundary phase during the sintering process itself, rather than requiring separate post-processing steps. The metal oxide or metal nitride is introduced and formed at the grain boundaries during sintering, integrating the eddy current suppression functionality into the base manufacturing process and avoiding additional complex manufacturing steps
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
Improves high-frequency characteristics by reducing eddy current loss and maintaining suitable inductance values, suitable for next-generation inductors.
Implementation Method 1
the grain boundary phase contains a metal oxide or a metal nitride that is an oxide or a nitride of a nonmagnetic metal
Implementation Method 2
a current flowing through a magnetic component including an element body including the magnetic material and wiring causes a magnetic flux to be locally concentrated between the powder particles of the soft magnetic powder in the magnetic material, which may increase eddy current loss
Implementation Method 3
a current flowing through a magnetic component including an element body including the magnetic material and wiring causes a magnetic flux to be locally concentrated between the powder particles
Implementation Method 4
A magnetic material that is a sintered body including a plurality of metal magnetic particles having a grain boundary phase
Data Source
AI summary
A magnetic material that is a sintered body including a plurality of metal magnetic particles having a grain boundary phase. The grain boundary phase contains a metal oxide or a metal nitride that is an oxide or a nitride of a nonmagnetic metal. The metal magnetic particles have an equivalent circle diameter of 0.29 μm or more and 2.33 μm or less (i.e., from 0.29 μm to 2.33 μm).