Inductor Insulator Composition for High-Frequency Q-Value
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Solution Overview
Problem
Inductor components with glass-based insulating materials face challenges in balancing strength and Q-value at high frequencies, as the addition of crystalline fillers enhances strength but increases dielectric loss and impairs conductor surface smoothing.
Innovation Solution
The inductor component design incorporates a filler-poor glass portion with reduced crystalline filler content around the inner electrode, utilizing an amorphous material containing B, Si, and K, which reduces dielectric loss and increases the Q-value by allowing liquid-phase sintering and skin effect benefits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crystalline filler is added to glass-based insulating material, then strength is enhanced, but dielectric loss increases and Q-value is not sufficiently increased
Solution Approach 1:
The patent applies local quality by creating a filler-poor glass portion with reduced crystalline filler content (5-30 wt%) specifically in the region surrounding the inner electrode, while other regions maintain normal filler content (15-35 wt%). This localized modification reduces dielectric loss in the critical area near the electrode where high-frequency currents flow, thereby increasing the Q-value, while other regions retain sufficient filler content to maintain overall structural strength.
2Strength
If crystalline filler is added to glass-based insulating material, then strength is enhanced, but conductor surface smoothing is impaired so as to increase loss
Solution Approach 1:
The patent creates a localized filler-poor glass portion surrounding the inner electrode where crystalline filler content is reduced to 5-30 wt%. During sintering, this region exhibits lower viscosity and better flow characteristics, enabling effective conductor surface smoothing. Other regions maintain normal filler content (15-35 wt%) to provide overall structural strength, thus resolving the contradiction between strength enhancement and surface smoothness.
3Loss of energy
If amorphous material is used around inner electrode, then dielectric loss is reduced and Q-value is increased, but strength may be reduced
Solution Approach 1:
The patent implements local quality by creating a filler-poor glass portion with 65-95 wt% amorphous material content specifically in the region surrounding the inner electrode, while other regions maintain balanced composition. This localized amorphous-rich region reduces dielectric loss and improves conductor surface smoothing, while the overall element assembly maintains sufficient strength through normal filler content in other regions and optimized global composition.
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 design enhances the strength of the inductor component, reduces dielectric loss, and increases the Q-value at high frequencies by optimizing the distribution and content of crystalline and amorphous materials, resulting in improved surface smoothness and reduced electric resistance.
Implementation Method 1
since the melting temperature of the crystalline filler is high, addition of the crystalline filler increases the rheology of a liquefied glass phase in a high-temperature range. As a result, smoothing of the conductor surface is impaired so as to increase loss.
Implementation Method 2
skin effect benefits
Data Source
AI summary
An inductor component includes an element assembly formed of an insulator material and an inner electrode arranged in the element assembly. The insulator material contains a base material formed of an amorphous material containing B, Si, O, and K and a crystalline filler and includes a filler-poor glass portion in a region along the inner electrode. The content of the crystalline filler in the filler-poor glass portion is lower than the content of the crystalline filler in the element assembly excluding the filler-poor glass portion.