Laminated Magnetic Thin-Strip Inductor Structure for Low-Strain Sintering
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Solution Overview
Problem
The existing methods for manufacturing inductor components using a build-up or molding method apply stress to the composite body, leading to strain in magnetic materials, which disrupts the magnetic characteristics and limits the selection of magnetic materials.
Innovation Solution
The use of an electronic component with an element body comprising laminated flat plate-shaped magnetic thin strips made of a sintered magnetic material, where a nonmagnetic layer and magnetic layer are formed using pastes, divided, and filled with nonmagnetic paste, and then fired to create a multilayer body with reduced strain, enhancing magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a build-up method or molding method is used to form the composite body, then the filling rate of inorganic filler can be increased to improve various characteristics, but stress is applied to the composite body during stamping which causes strain in magnetic material and disturbs sufficient exhibition of magnetic characteristics
Solution Approach 1:
The magnetic layer is divided into multiple magnetic thin strips by forming grooves between them. This segmentation allows each strip to be independently sintered with reduced internal stress, preventing strain distortion while maintaining high filling rates. The divided structure enables better stress distribution during the sintering process.
Solution Approach 2:
The patent changes the manufacturing parameters by using a sintering process instead of conventional molding or build-up methods. The magnetic layers are sintered at high temperature to form a sintered body structure, which fundamentally alters the material properties and stress characteristics, enabling high filling rates without magnetic characteristic degradation.
2Ease of manufacture
If conventional molding or build-up methods are used, then manufacturing process is simpler, but strain of magnetic material due to stress during stamping reduces the degree of freedom in selecting magnetic material
Solution Approach 1:
By changing to a sintering process with specific temperature and time parameters, the patent enables the use of a broader range of magnetic materials that would be unsuitable for conventional molding methods. The sintering parameters can be optimized for different magnetic material compositions, providing greater material selection freedom.
Solution Approach 2:
The divided magnetic layer structure with grooves allows each segment to be processed independently during sintering, reducing interdependent constraints. This enables greater flexibility in material selection as each strip can be optimized for specific magnetic properties without being constrained by the overall composite body formation process.
3Reliability
If magnetic thin strips are made of sintered body, then strain of magnetic thin strip is reduced in sintering process and characteristics are improved, but manufacturing process becomes more complex with multiple steps including forming nonmagnetic layer, magnetic layer, dividing, and filling
Solution Approach 1:
The patent combines multiple functions into integrated process steps. The nonmagnetic layers serve both as structural support and as stress-relief interfaces during sintering. The grooves serve both as dividers for stress reduction and as channels for nonmagnetic paste filling. This merging of functions reduces the need for separate processing steps.
Solution Approach 2:
The nonmagnetic paste filled into grooves acts as an intermediary material that facilitates the sintering process. It provides a buffer zone that reduces stress concentration at interfaces between magnetic strips, enabling the sintering process to proceed with less distortion while maintaining the divided 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
This approach reduces strain in the magnetic thin strips during the sintering process, improving the magnetic characteristics and inductance of the inductor component, while allowing for higher permeability and reduced eddy current losses.
Implementation Method 1
firing the multilayer body to make the wiring pattern to a wiring line of a sintered body, to make the nonmagnetic layer to an interlayer nonmagnetic portion of a sintered body, and to make the magnetic layer to a magnetic thin strip of a sintered body
Data Source
AI summary
An electronic component with improved characteristics includes an element body and an inductor wiring as a wiring line. The element body includes multiple flat plate-shaped magnetic thin strips made of a magnetic material of a sintered body. The multiple magnetic thin strips are laminated in a lamination direction orthogonal to a main face of one of the magnetic thin strips. The inductor wiring extends along the main face inside the element body.