Multilayer Inductor with Glass-Diffused Magnetic Layers
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Solution Overview
Problem
Conventional multilayer inductors face limitations in further improving direct-current superposition characteristics due to magnetic saturation, which affects the performance of electronic components.
Innovation Solution
The electronic component incorporates a laminate structure with magnetic layers and non-magnetic layers containing glass, where the glass diffuses into the magnetic layers, reducing magnetic permeability adjacent to the non-magnetic layers, thereby creating low-magnetic-permeability portions that help suppress magnetic saturation, and the component is manufactured through a process involving ceramic green sheets, via-hole conductors, and firing to achieve an open magnetic circuit structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-magnetic layers are added to suppress magnetic saturation, then direct-current superposition characteristics improve, but device complexity increases
Solution Approach 1:
The patent uses composite materials by combining magnetic layers with non-magnetic layers containing glass in a laminate structure. The glass-containing non-magnetic layers diffuse glass into the magnetic layers during firing, creating regions with reduced magnetic permeability that suppress magnetic saturation while maintaining structural integrity.
Solution Approach 2:
The patent applies local quality by creating regions with different magnetic permeability within the magnetic layers. The portions adjacent to glass-containing non-magnetic layers have lower magnetic permeability due to glass diffusion, while other portions maintain original magnetic properties, allowing localized suppression of magnetic saturation.
2Reliability
If glass is diffused into magnetic layers to reduce magnetic permeability, then magnetic saturation is suppressed, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses parameter changes by controlling the firing temperature and composition of glass-containing non-magnetic layers to achieve desired glass diffusion into magnetic layers. By adjusting these parameters, the manufacturing process controls the extent of magnetic permeability reduction in specific regions.
3Reliability
If the glass ratio in non-magnetic layers is increased to improve direct-current characteristics, then magnetic saturation suppression improves, but chip strength may decrease
Solution Approach 1:
The patent optimizes the glass ratio parameter in non-magnetic layers to achieve the best balance between direct-current superposition characteristics and chip strength. The glass ratio is controlled within specific ranges to ensure sufficient glass diffusion for magnetic saturation suppression while maintaining adequate mechanical strength.
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
This approach enhances direct-current superposition characteristics by reducing magnetic saturation and maintaining chip strength, with optimal results achieved when the borosilicate glass ratio is between 30% and 70% by volume in the non-magnetic layers.
Implementation Method 1
by diffusion of the glass from the non-magnetic layer to the magnetic layers
Data Source
AI summary
A laminate has a structure in which magnetic layers and a non-magnetic layer containing glass are stacked. A coil is incorporated in the laminate. The magnetic permeability μ2 in portions (low-magnetic-permeability portions), of the magnetic layers, which are adjacent to the non-magnetic layer and into which the glass diffuses is lower than the magnetic permeability μ1 in portions (high-magnetic-permeability portions), of the magnetic layers, which are not adjacent to the non-magnetic layer.