Metal-Particle Inductor Structure for Permeability and Withstand Voltage
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Solution Overview
Problem
Inductors using soft magnetic metal materials face challenges with low magnetic permeability and withstand voltage characteristics, which are inferior to ferrite materials, necessitating the development of a solution that enhances both properties.
Innovation Solution
An inductor design incorporating a magnetic base body with soft magnetic metal particles, specifically an Fe—Si alloy, and an internal conductor with a rectangular parallelepiped shape, where the magnetic base body is optimized with a peak intensity ratio of 2 or more in a Raman spectrum, and an insulating film is used between the external electrodes and the magnetic base body to improve magnetic permeability and withstand voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If soft magnetic metal material is used as the magnetic base body, then the inductor can handle large electric current, but the magnetic permeability and withstand voltage characteristic deteriorate
Solution Approach 1:
The patent uses a composite material consisting of soft magnetic metal particles (Fe-Si alloy) combined with an insulating resin matrix. This composite structure allows the magnetic base body to maintain high magnetic permeability while the insulating resin provides enhanced withstand voltage characteristics, resolving the contradiction between current handling capability and voltage resistance.
Solution Approach 2:
The insulating resin acts as an intermediary material between the soft magnetic metal particles. It provides electrical insulation to improve withstand voltage characteristics while allowing the magnetic particles to maintain their magnetic properties for handling large currents, thus mediating between the two conflicting requirements.
2Power
If soft magnetic metal material is used as the magnetic base body, then the inductor can handle large electric current, but the magnetic permeability deteriorates
Solution Approach 1:
The patent employs a composite material where soft magnetic metal particles (providing high current handling capability) are embedded in an insulating resin matrix (preserving magnetic field integrity). This composite structure maintains high magnetic permeability while enabling large current handling, resolving the contradiction between these two properties.
Solution Approach 2:
The magnetic base body has non-uniform local properties: regions with higher concentration of soft magnetic metal particles provide current handling capability, while the resin-rich regions maintain magnetic field integrity and permeability. This local quality variation allows simultaneous optimization of both current handling and magnetic permeability.
Data Source
AI summary
An inductor includes a magnetic base body including soft magnetic metal particles containing iron, first and second external electrodes provided on the magnetic base body, and an internal conductor provided in the magnetic base body, with one end thereof electrically connected to the first external electrode and the other end thereof electrically connected to the second external electrode, the internal conductor extending linearly from the first external electrode to the second external electrode in plan view. The magnetic base body is configured so that a peak intensity ratio is 2 or more between a peak intensity of a first peak and a peak intensity of a second peak in a Raman spectrum obtained by using an excitation laser with a wavelength of 488 nm. The first peak is around a wave number of 712 cm−1, and the second peak is around a wave number of 1320 cm−1.