Multilayer Coil Resistivity Stabilization via Vanadium Doping
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Solution Overview
Problem
Multilayer coil components with copper as an internal conductor face variations in resistivity during industrial-scale production, leading to issues with plating spreading when outer electrodes are applied, due to uneven oxygen partial pressures in large furnaces.
Innovation Solution
Incorporating vanadium and controlling the amounts of iron, zinc, manganese, and copper in the magnetic material, along with firing in a low-oxygen atmosphere, helps stabilize resistivity and prevent unwanted plating spreading during mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper is used as an internal conductor to reduce cost and improve conductivity, then manufacturing cost decreases and electrical conductivity improves, but resistivity varies during mass production due to uneven oxygen partial pressure in large furnaces
Solution Approach 1:
The patent modifies the chemical composition parameters of the ferrite material by adding vanadium (0.1-5.0 wt%) and adjusting the Fe-Zn-Mn-Cu ratio. This parameter change makes the ferrite material resistant to reduction even under low oxygen partial pressure conditions during mass production firing, thereby maintaining consistent resistivity and preventing plating spreading.
2Productivity
If large furnaces are used for mass production to increase productivity, then production volume increases, but oxygen partial pressure becomes uneven causing resistivity variations
Solution Approach 1:
The patent changes the chemical composition parameters of the ferrite material by incorporating vanadium and adjusting elemental ratios, making the material insensitive to oxygen partial pressure variations. This allows mass production in large furnaces to proceed without compromising resistivity consistency, thus maintaining both high productivity and manufacturing precision.
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 ensures consistent resistivity and reduces undesired plating spreading, enabling stable mass production of multilayer coil components with copper-containing internal conductors.
Implementation Method 1
the Fe of the ferrite material is reduced from a trivalent to a divalent form and the resistivity of the multilayer coil component decreases
Implementation Method 2
an organic binder in the multilayer body is removed by heating at a temperature of 300 to 400° C. to burn before the multilayer body is fired
Data Source
AI summary
A multilayer coil component including: a magnetic part that contains Fe, Zn, V, and Ni and optionally contains Mn and/or Cu; and a conductor part that contains copper. In the magnetic part, Fe is in an amount of 34.0 to 48.5 mol % expressed as Fe2O3 equivalent, Zn is in an amount of 6.0 to 45.0 mol % expressed as ZnO equivalent, Mn is in an amount of 0 to 7.5 mol % expressed as Mn2O3 equivalent, Cu is in an amount of 0 to 5.0 mol % expressed as CuO equivalent, and V is in an amount of 0.5 to 5.0 mol % expressed as V2O5 equivalent, with respect to the total amount of Fe expressed as Fe2O3 equivalent, Zn expressed as ZnO equivalent, V expressed as V2O5 equivalent, and Ni expressed as NiO equivalent, and optionally present Cu expressed as CuO equivalent and optionally present Mn expressed as Mn2O3 equivalent.