Multilayer Coil Composition for Uniform Oxide Insulation
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Solution Overview
Problem
The existing multilayer coil components face challenges in achieving optimal insulating properties and magnetic performance due to variations in oxide film thickness, which affects the component's thickness and magnetic properties, leading to increased thickness and reduced advantages of thickness reduction.
Innovation Solution
The use of soft magnetic alloy grains containing Fe, Si, and at least one of Cr and Al, with an oxide layer composed of Si and these elements, where Si content is higher than Cr and Al, to ensure uniform oxide film thickness and improved insulating properties, is implemented, along with a specific heat treatment process in a controlled oxygen atmosphere.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat treatment is performed in air to form oxide film on metal magnetic material, then insulating property is improved, but oxide film thickness becomes non-uniform (thick at surface, thin at interior) causing magnetic property degradation
Solution Approach 1:
The invention changes the chemical composition parameters of the magnetic alloy by adding specific elements (Al: 0.01-5 mass%, Si: 0.01-5 mass%, Cr: 0.01-5 mass%) to control oxide film formation behavior. This compositional modification enables uniform oxide film thickness while maintaining adequate insulating property, resolving the contradiction between insulation and thickness uniformity.
2Reliability
If oxide film thickness is increased to ensure insulating property in interior, then insulation is improved, but magnetic properties deteriorate due to excessive thickness at surface
Solution Approach 1:
By optimizing the alloy composition parameters (specifically adding Al, Si, and Cr within defined ranges), the invention achieves uniform oxide film formation that provides sufficient insulation without excessive thickness. This parameter optimization ensures both adequate insulating property and preserved magnetic properties.
3Reliability
If internal conductor spacing is widened to ensure sufficient insulation, then insulating property is improved, but component thickness increases losing multilayer advantage
Solution Approach 1:
The invention changes the oxide film formation parameters through alloy composition modification, achieving uniform and adequate oxide film thickness that provides sufficient insulation without requiring increased conductor spacing. This enables maintenance of compact multilayer structure while ensuring adequate insulation.
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 results in a multilayer coil component with excellent magnetic properties and reduced thickness, allowing for narrower internal conductor spacing and enhanced electrical insulation, maintaining the advantage of thickness reduction while improving magnetic permeability.
Implementation Method 1
an oxide layer formed around the soft magnetic alloy grains to bond the soft magnetic alloy grains together
Implementation Method 2
heat-treat it for approx. 2 hours at approx. 700° C. in the air or other oxidizing atmosphere
Data Source
AI summary
Magnetic layers of the multilayer coil component are constituted by: soft magnetic alloy grains 21 containing Fe, Si, and at least one of Cr and Al, as constituent elements; and an oxide layer 22 formed around the soft magnetic alloy grains to bond the soft magnetic alloy grains together, and also containing Si as well as at least one of Cr and Al as constituent elements, where the content of Si based on mass is higher than the total content of Cr and Al. The multilayer coil component can have a small thickness and offer excellent magnetic properties.