Magnetic Base Body Oxide Structure for High Permeability Insulation
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Solution Overview
Problem
The formation of Fe oxide films, particularly those consisting mainly of hematite, on the surface of metal magnetic particles in magnetic base bodies reduces magnetic permeability, which is detrimental for high-current applications in electronic devices.
Innovation Solution
A manufacturing method involving a first heat treatment to form oxide layers of Si, Zr, or Ti on the metal magnetic particle surfaces, followed by a reducing atmosphere to create isolated metal Fe particles and optionally Cr particles, enhancing magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an Fe oxide film consisting mainly of hematite is formed on the surface of metal magnetic particles to prevent resistance and dielectric strength voltage deterioration, then insulation property is improved, but magnetic permeability is reduced
Solution Approach 1:
The oxide film is segmented into a multi-layer structure with an inner layer containing Fe oxide and an outer layer containing oxide of element A (Si, Zr, Al, or Ti). This segmentation allows the inner layer to provide insulation while the outer layer prevents hematite formation, thus maintaining magnetic permeability while ensuring insulation property.
Solution Approach 2:
The oxide film is formed as a composite material consisting of Fe oxide and oxide of element A in different layers. The Fe oxide layer provides insulation, while the oxide of element A layer prevents the formation of hematite, thereby maintaining soft magnetic properties. This composite structure resolves the contradiction between insulation requirement and magnetic permeability preservation.
2Strength
If a Cr oxide film is formed on the surface of metal magnetic particles, then corrosion resistance is improved, but magnetic permeability is reduced due to Cr oxide having no soft magnetism property
Solution Approach 1:
The harmful Cr oxide layer is extracted/removed from the surface oxide film. Instead of forming a Cr oxide film, the patent forms an oxide film containing Fe oxide and oxide of element A, eliminating the Cr oxide that would reduce magnetic permeability while maintaining corrosion resistance through the protective oxide of element A layer.
Solution Approach 2:
The composition parameters of the oxide film are changed by controlling the oxidation process to form Fe oxide and oxide of element A in specific proportions and layers, rather than forming Cr oxide. This parameter change ensures the oxide film provides both corrosion resistance and maintains soft magnetic 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
Improves magnetic permeability by maintaining soft magnetic properties while ensuring insulation, suitable for high-current applications in electronic components.
Implementation Method 1
a first heat treatment to form oxide layers of Si, Zr, or Ti on the metal magnetic particle surfaces
Implementation Method 2
followed by a reducing atmosphere to create isolated metal Fe particles
Data Source
AI summary
A magnetic base body includes plural metal magnetic particles including a first metal magnetic particle and a second metal magnetic particle adjacent to the first metal magnetic particle, each metal magnetic particle including Fe, and plural metal Fe particles including metal Fe. The plural metal Fe particles are disposed separately from each other between an insulating first oxide layer and an insulating second oxide layer. The first oxide layer includes oxide of an element A disposed on a surface of the first metal magnetic particle. The second oxide layer includes oxide of an element B disposed on a surface of the second metal magnetic particle. The element A is at least one element selected from a group consisting of Si, Zr, Al, and Ti, and the element B is at least one element selected from the group consisting of Si, Zr, Al, and Ti.