Laminated Electronic Component Ni-Cu Magnetic Gaps
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Solution Overview
Problem
Conventional laminated-type electronic components experience deterioration in magnetic properties and temperature characteristics due to the formation of ferrite layers with ununiform compositions at the interfaces between magnetic material layers and magnetic gaps, leading to a negative temperature coefficient and abrupt decrease in inductance value, especially when exposed to high temperatures.
Innovation Solution
The use of magnetic gaps formed from a compound of Ni and Cu, eliminating Zn to prevent the formation of ferrite layers with a Curie point near room temperature, thereby maintaining stable magnetic properties across temperature variations and enhancing the structural design correlation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Zn-based ferrite is used in magnetic gaps to secure preferable junctions, then junction quality between magnetic material layers and magnetic gaps is improved, but ununiform compositions and unstable magnetic characteristics occur due to element dispersion during burning
Solution Approach 1:
The patent introduces a specific ferrite composition (Ni0.7Zn0.3Fe2O4 with 30-70 wt% NiO and 7-30 wt% ZnO) as an intermediary material in the magnetic gap that acts as a buffer zone. This intermediary composition prevents harmful element dispersion while maintaining good junction quality between magnetic material layers and magnetic gaps, resolving the contradiction between junction quality and compositional stability.
Solution Approach 2:
The patent changes the compositional parameters of the ferrite in magnetic gaps by specifying precise ranges of NiO (30-70 wt%) and ZnO (7-30 wt%). This parameter optimization ensures that the ferrite maintains stable magnetic characteristics while providing good junction properties, preventing the ununiform composition problem that occurs with conventional compositions.
2Ease of manufacture
If Ni ferrite disperses toward magnetic gaps forming mixture composition, then junction formation is facilitated, but Curie point decreases to vicinity of room temperature causing rapid magnetic property loss
Solution Approach 1:
The patent optimizes the compositional parameters of the ferrite in magnetic gaps by controlling NiO content at 30-70 wt% and ZnO content at 7-30 wt%. This parameter control raises the Curie point above room temperature while maintaining good junction formation, preventing the rapid magnetic property loss that occurs when Curie point is near room temperature.
Solution Approach 2:
The patent creates a composite ferrite material with specific NiO-ZnO composition ratios in the magnetic gaps. This composite material structure facilitates junction formation while maintaining a Curie point above room temperature, resolving the contradiction between ease of manufacture and temperature stability.
3Stability of the object's composition
If SiO2 is used in magnetic gaps to cancel negative temperature characteristics, then temperature characteristics improve, but magnetic permeability of ferrite deteriorates due to SiO2 dispersion
Solution Approach 1:
The patent replaces SiO2 with a ferrite-based material composition that inherently provides stable temperature characteristics without the harmful side effects. This alternative material achieves the temperature stability function without compromising magnetic permeability, effectively substituting the problematic SiO2 material.
Solution Approach 2:
The patent uses a composite ferrite material with optimized NiO-ZnO composition in the magnetic gaps that provides both stable temperature characteristics and maintained magnetic permeability. This composite material eliminates the need for SiO2 while achieving the same temperature compensation function without the harmful dispersion effects.
4Reliability
If line widths of conductive patterns are increased to reduce DC resistance, then DC superimposed allowable current value increases, but component size increases
Solution Approach 1:
The patent optimizes the magnetic gap composition parameters (NiO: 30-70 wt%, ZnO: 7-30 wt%) to achieve stable magnetic characteristics and prevent magnetic saturation. This allows the use of smaller conductive pattern line widths while maintaining high DC superimposed allowable current values, thereby reducing component size without sacrificing current capability.
Solution Approach 2:
The patent replaces conventional magnetic gap materials with optimized ferrite compositions that provide better magnetic stability and prevent saturation. This material substitution allows for more efficient current handling with smaller conductor dimensions, reducing overall component volume while maintaining or improving DC current capability.
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 allows for a significant increase in DC superimposed allowable current value without compromising temperature characteristics, resulting in improved temperature stability and accuracy of design, with minimal variation in inductance value across temperature changes.
Implementation Method 1
it has been known that such a composition has the Curie point in vicinity of a room temperature (25° C.), and if the temperature increases greater than the room temperature, its magnetic property is rapidly lost
Data Source
AI summary
A laminated-type electronic component including: plural magnetic material layers; plural conductive patterns; a laminated layer body formed by laminating the plural magnetic material layers and the plural conductive patterns; a coil formed in the laminated layer body by connecting the conductive patterns between the magnetic material layers; and at least one magnetic gap formed in the laminated layer body, wherein the magnetic gaps are formed of a compound of Ni and Cu.