Magnetic Core Oxide Layer Permeability Insulation
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Solution Overview
Problem
Magnetic cores for coil components require high initial permeability, but achieving this often results in mold breakage during high-pressure consolidation and compromised insulation properties due to increased heat treatment temperatures.
Innovation Solution
A magnetic core formed by heat-treated Fe-based alloy particles with an oxide layer containing Fe oxide and Fe3Al, where the peak intensity ratios of X-ray diffraction peaks are controlled to enhance initial permeability, and the oxide layer acts as an insulating layer between particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-pressure consolidation is used to increase green compact density, then initial permeability is improved, but mold breakage occurs and shape freedom is restricted
Solution Approach 1:
The invention changes the chemical composition parameters of the magnetic alloy powder by adding Al (1-10 mass%) and Cr (1-10 mass%) elements, which enables the formation of a protective oxide layer during heat treatment. This oxide layer provides bonding between particles and maintains insulation properties, allowing achievement of high initial permeability without requiring excessive consolidation pressure that would break the mold
2Manufacturing precision
If heat treatment temperature is increased to increase space factor, then initial permeability is improved, but insulation properties are compromised due to sintering
Solution Approach 1:
The invention introduces an oxide layer as an intermediary substance formed on the particle surfaces during heat treatment. This oxide layer acts as a mediator that provides bonding between magnetic alloy particles while simultaneously maintaining electrical insulation properties, thus resolving the contradiction between achieving high initial permeability (requiring particle bonding) and maintaining insulation properties (requiring particle separation)
Solution Approach 2:
The invention creates a composite structure consisting of magnetic alloy particles with surface oxide layers. The composite material comprises the metallic magnetic alloy core providing magnetic properties and the oxide layer providing both bonding and insulation functions, enabling simultaneous achievement of high initial permeability and maintained insulation 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 magnetic core achieves high initial permeability while maintaining insulation properties and preventing mold breakage, with the oxide layer effectively bonding particles and reducing core loss.
Implementation Method 1
heat-treated in an oxygen-containing atmosphere to form an oxide layer obtained by the oxidation of the alloy particles on the surface of the particles
Implementation Method 2
insulation properties are imparted to a magnetic core
Implementation Method 3
The soft magnetic alloy particles are bonded via the oxide layer
Implementation Method 4
A magnetic core obtained by consolidating a green compact of the magnetic alloy powder has a high saturation magnetic flux density
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~3
AI summary
Provided are a magnetic core having a high initial permeability and a coil component including the same. The magnetic core has an X-ray diffraction spectrum of the magnetic core measured using Cu-Kα characteristic X-rays, wherein a peak intensity ratio (P1/P2) of a peak intensity P1 of a diffraction peak of an Fe oxide having a corundum structure appearing in a vicinity of 2θ = 33.2° to a peak intensity P2 of a diffraction peak of the Fe-based alloy having a bcc structure appearing in a vicinity of 2θ = 44.7° is 0.015 or less; and in the X-ray diffraction spectrum, a peak intensity ratio (P3/P2) of a peak intensity P3 of a superlattice peak of an Fe3Al ordered structure appearing in a vicinity of 2θ = 26.6° to the peak intensity P2 is 0.015 or more and 0.050 or less.