Magnetic Composition for High-Frequency Inductors
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Solution Overview
Problem
Inductors used in electronic devices face challenges in achieving high inductance while operating in high frequency bands, particularly due to limitations in magnetic permeability and power consumption.
Innovation Solution
A magnetic composition comprising coarse non-crystalline iron-based powder, medium crystalline iron-based powder, and fine nickel powder is used, with specific particle size ranges and ratios to enhance inductance and self-resonance frequency, including an inductor design with a coil part and external electrodes, and a cover layer to optimize magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional single-material magnetic compositions are used, then manufacturing is simple, but inductance is insufficient and high-frequency performance is limited
Solution Approach 1:
The patent applies composite materials by combining three distinct magnetic powder types (coarse non-crystalline iron-based powder, medium crystalline iron-based powder, and fine nickel powder) in specific size ranges and proportions. This multi-material composition enables simultaneous optimization of inductance (through high magnetic permeability from fine powder), self-resonance frequency (through size-distributed powder structure), and manufacturing feasibility (through established ceramic processing techniques for powder mixing and sintering)
2Manufacturing precision
If high magnetic permeability materials are used to increase inductance, then inductance increases, but self-resonance frequency decreases limiting high-frequency operation
Solution Approach 1:
The patent segments the magnetic composition into three distinct particle size categories: coarse powder (5-10 μm) for structural framework, medium powder (2-5 μm) for intermediate properties, and fine powder (0.5-2 μm) for high magnetic permeability. This segmentation allows each size fraction to contribute differently to the overall performance, with fine powder enhancing inductance while the coarse and medium powders maintain self-resonance frequency in the high-frequency range
Solution Approach 2:
The patent applies local quality by assigning different functional roles to different particle size regions within the composite. The fine nickel powder (0.5-2 μm) provides high magnetic permeability for inductance enhancement in specific local regions, while the coarse non-crystalline iron-based powder (5-10 μm) and medium crystalline powder (2-5 μm) provide structural stability and high-frequency characteristics in other regions, creating a spatially differentiated functional structure
3Manufacturing precision
If copper wire is wound around ferrite core to achieve high inductance, then inductance increases, but DC resistance increases leading to higher power consumption
Solution Approach 1:
The patent replaces the mechanical wire-winding system with a ceramic-based multilayer inductor structure. Instead of winding copper wire around a ferrite core (mechanical assembly), the invention uses stacked ceramic layers with embedded magnetic powder compositions and conductive patterns formed through printing and sintering processes. This substitution eliminates the need for extensive copper wiring, thereby reducing DC resistance and power consumption while achieving the required inductance through the magnetic powder composition and layer structure
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 increases inductance and allows for operation in high frequency bands up to 100 MHz, reducing power consumption and eddy current loss while maintaining high saturation current and powder filling rates.
Implementation Method 1
An inductor is a coil component commonly used as an electronic component in electronic devices such as cellular phones and personal computers (PCs). Such an inductor may respond to changes in magnetic flux to generate inductive electromotive force.
Implementation Method 2
Since the multilayer inductors has a structure in which a stereoscopic coil is covered by ferrite, multilayer inductors are inductors capable of decreasing magnetic leakage due to a magnetic shielding effect of the ferrite
Data Source
AI summary
A magnetic composition includes: coarse powder containing a non-crystalline iron-based material; medium powder containing a crystalline iron-based material; and fine powder containing nickel. A ratio of the coarse powder and the medium powder is in a range of 65:35 to 80:20, and the amount of the fine powder is in a range of 3 wt % to 7 wt % on the basis of a total weight of the coarse powder and the medium powder.