High-Frequency Magnetic Material with Oxide Phase and Metal Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high-frequency magnetic materials lack superior magnetic characteristics and thermal stability at high frequencies, and existing production methods are costly and yield inefficient results.
Innovation Solution
A high-frequency magnetic material composed of an oxide phase with a solid solution of specific elements and magnetic metal particles (Fe and Co) deposited on the surface and inside, with a method involving the reduction of precursor salts to achieve a high filling factor of magnetic metal particles, enhancing magnetic permeability and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ferrite or amorphous alloy is used for inductor at high frequencies (1 MHz or more), then low loss (low μ′′) and high magnetic permeability (high μ′) are achieved at 1 MHz to 10 MHz, but at higher frequencies (10 MHz or more), the real part μ′ of magnetic permeability decreases and sufficient characteristics are not acquired
Solution Approach 1:
The invention uses a composite material consisting of an oxide phase (such as MgO, Al2O3, SiO2, CaO, ZrO2, TiO2, HfO2, ZnO, MnO, rare-earth oxide, BaO, or SrO) and magnetic metal particles (Fe or Co) dispersed within and on the oxide. This composite structure combines the thermal stability of oxide with the magnetic properties of metal particles, enabling superior magnetic characteristics at high frequencies while maintaining thermal stability, thereby resolving the frequency-performance limitation of conventional ferrite and amorphous alloy materials.
2Reliability
If thin-film technique (sputtering or plating) is used to manufacture inductor, then magnetic characteristics at high frequencies can be improved, but large-size facility is required, precise control of film thickness is needed, cost increases, yield decreases, and long hours of thermal stability at high temperatures and high humidity is lacking
Solution Approach 1:
The invention replaces expensive and complex thin-film manufacturing processes with a simpler, more cost-effective method using conventional ceramic processing techniques. The oxide phase with dispersed magnetic metal particles can be manufactured using standard sintering processes, eliminating the need for large-size sputtering facilities and precise film thickness control systems, thereby reducing cost and improving yield while maintaining high-frequency magnetic characteristics.
3Adaptability or versatility
If binder molding technique is used to manufacture electromagnetic wave absorber, then ferrite particles, carbonyl iron particles, FeAlSi flakes, FeCrAl flakes can be mixed with resin, but at high frequencies (1 GHz or more), extremely-low μ′ and μ′′ are exhibited and sufficient characteristic is not acquired
Solution Approach 1:
The invention creates a composite material where magnetic metal particles (Fe or Co) are dispersed within an oxide phase matrix. This composite structure provides both the electromagnetic wave absorption capability needed for adaptability and maintains superior magnetic characteristics at high frequencies (1 GHz or more), overcoming the frequency limitation of conventional binder molding techniques that use ferrite particles mixed with resin.
4Reliability
If material is synthesized by mechanical alloying technique, then magnetic material can be produced, but long hours of thermal stability is lacking and yield is low
Solution Approach 1:
The invention replaces complex mechanical alloying techniques with simpler conventional ceramic processing methods. The oxide phase with dispersed magnetic metal particles can be manufactured using standard mixing, shaping, and sintering processes, eliminating the need for prolonged mechanical alloying treatment. This approach improves yield by using more efficient manufacturing processes while achieving long hours of thermal stability through the oxide-magnetic metal composite structure.
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 material exhibits superior magnetic characteristics and thermal stability at high frequencies, enabling its use as both a high-permeability component and electromagnetic wave absorber, with improved manufacturing efficiency and cost-effectiveness.
Implementation Method 1
a method involving the reduction of precursor salts to achieve a high filling factor of magnetic metal particles
Data Source
AI summary
A high-frequency magnetic material is provided and includes: an oxide phase including: a first oxide of a first element being at least one selected from the group consisting of Mg, Al, Si, Ca, Zr, Ti, Hf, Zn, Mn, a rare-earth element, Ba, and Sr, and a second oxide of a second element being at least one selected from the group consisting of Li, Na, K, Rb, Cs, Be, Mg, Ca, Sr, Ba, and Zn, the first oxide and at least a part of the second oxide being formed into a solid solution; and magnetic metal particles including at least one of Fe and Co and having a particle size of 1 to 100 nm, the magnetic metal particles being deposited on a surface and inside of the oxide phase, the magnetic metal particles occupying 50% of a volume of the high-frequency magnetic material exclusive of a void.