Magnetic Base Body Insulation Film for Strength-Filling Balance
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Solution Overview
Problem
The existing magnetic base bodies face a trade-off between mechanical strength and filling rate, where reducing insulation film thickness enhances bonding strength but decreases filling rate, and increasing film thickness improves filling rate but compromises mechanical strength.
Innovation Solution
A magnetic base body design featuring soft magnetic metal particles with insulation films comprising a first oxide region of amorphous Al oxide and a second oxide region, strategically positioned between particles to enhance bonding while maintaining high filling rates, utilizing a specific oxide composition and distribution to optimize both properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the insulation film is reduced to enhance bonding strength, then the bonding force between adjacent soft magnetic metal particles is improved, but the filling rate of soft magnetic metal particles in the magnetic base body is reduced
Solution Approach 1:
The patent applies local quality by creating a non-uniform insulation film structure where the film thickness varies in different regions. Specifically, the insulation film has a first thickness in the circumferential direction and a second thickness in the radial direction, with the first thickness being greater than the second thickness. This localized variation allows the film to provide sufficient bonding strength where needed while maintaining high filling rate by reducing thickness in other regions.
Solution Approach 2:
The patent changes the geometric parameters of the insulation film by defining different thickness values in different directions (circumferential vs radial). This parameter modification enables the insulation film to simultaneously satisfy the requirements for bonding strength and filling rate, resolving the technical contradiction between these two properties.
2Quantity of substance
If the thickness of the insulation film is increased to maintain high filling rate, then the filling rate of soft magnetic metal particles is improved, but the bonding force between adjacent particles is weakened
Solution Approach 1:
The patent applies local quality by creating a non-uniform insulation film structure where the film thickness varies in different regions. Specifically, the insulation film has a first thickness in the circumferential direction and a second thickness in the radial direction, with the first thickness being greater than the second thickness. This localized variation allows the film to provide sufficient bonding strength where needed while maintaining high filling rate by reducing thickness in other regions.
Solution Approach 2:
The patent changes the geometric parameters of the insulation film by defining different thickness values in different directions (circumferential vs radial). This parameter modification enables the insulation film to simultaneously satisfy the requirements for bonding strength and filling rate, resolving the technical contradiction between these two properties.
3Reliability
If a uniform thick insulation film is applied to all surfaces of soft magnetic metal particles, then the insulation property is improved, but the mechanical strength of the magnetic base body is deteriorated
Solution Approach 1:
The patent applies local quality by creating a non-uniform insulation film structure where the film thickness varies in different regions. Specifically, the insulation film has a first thickness in the circumferential direction and a second thickness in the radial direction, with the first thickness being greater than the second thickness. This localized variation allows the film to provide sufficient bonding strength where needed while maintaining high filling rate by reducing thickness in other regions.
Solution Approach 2:
The patent changes the geometric parameters of the insulation film by defining different thickness values in different directions (circumferential vs radial). This parameter modification enables the insulation film to simultaneously satisfy the requirements for bonding strength and filling rate, resolving the technical contradiction between these two properties.
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 solution effectively improves the bonding strength between soft magnetic metal particles while maintaining a high filling rate, thereby enhancing the mechanical strength and insulation performance of the magnetic base body.
Implementation Method 1
In the heating treatment, an additive element (e.g., Si, Cr, or Al) contained in a precursor powder particle moves to the surface of the precursor powder particle, and is oxidized. For this reason, an oxidized coating film that has an insulating property and contains an oxide of an element contained in precursor powder is formed on the surface of a soft magnetic metal particle.
Implementation Method 2
a mixture resin composition formed of a mixture of resin and precursor powder made from a soft magnetic material and then heating the mixed resin composition
Implementation Method 3
As a result of the heating treatment, the coating layer is turned into a third oxide layer that contains an Si oxide, and a fourth oxide layer that contains Fe is formed on the outer surface of the coating layer.
Data Source
AI summary
Disclosed herein is a magnetic base body including a plurality of soft magnetic metal particles each containing Fe, and a plurality of insulation films that cover respective surfaces of the soft magnetic metal particles. The plurality of soft magnetic metal particles include a first soft magnetic metal particle, the plurality of insulation films include a first insulation film that covers a surface of the first soft magnetic metal particle, and the first insulation film is disposed between the first soft magnetic metal particle and a soft second magnetic metal particle that is adjacent to the first soft magnetic metal particle, and the first insulation film includes a first oxide region that is composed of mainly an amorphous Al oxide and a second oxide region that covers a portion of the surface of the first soft magnetic metal particle and that is composed of mainly an oxide of an element A.