Multilayer Inductor Interdiffusion Layer Formation
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Solution Overview
Problem
Conventional multilayer inductors face challenges in maintaining satisfactory inductance and dc bias characteristics due to increased production costs and potential cracking issues caused by complex processing of nonmagnetic layers and the need for precise placement of magnetic and nonmagnetic materials.
Innovation Solution
A production method for multilayer inductors involving the formation of interdiffusion layers by superimposing magnetic and nonmagnetic sheets, where the magnetic layer is formed on the nonmagnetic sheet inside the conductive pattern and then fired to induce interdiffusion, eliminating the need for complex processing and reducing production costs while ensuring desired characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rectangular magnetic layers are buried in the central region of nonmagnetic layers, then inductance and dc bias characteristics can be ensured, but production cost increases due to complex processing of nonmagnetic layers
Solution Approach 1:
The magnetic layers themselves perform the function of defining the central region structure. By forming magnetic layers with conductive patterns directly, the patent eliminates the need for separate nonmagnetic layer processing to create central regions, allowing the magnetic layers to serve both structural and functional purposes simultaneously
Solution Approach 2:
The patent removes the complex nonmagnetic layer processing step entirely. Instead of burying magnetic layers within processed nonmagnetic layers, the invention extracts this unnecessary intermediate step and forms the magnetic layers with their required structures directly, simplifying the manufacturing process while maintaining the desired inductance and dc bias characteristics
2Reliability
If rectangular magnetic layers are buried in the central region of nonmagnetic layers, then inductance and dc bias characteristics can be ensured, but cracking occurs due to weakened strength in boundary regions
Solution Approach 1:
The patent creates a composite structure where magnetic layers with different Zn component contents are combined. The first magnetic layers have lower Zn content while the second magnetic layers have higher Zn content, forming a composite material system that provides both the required electromagnetic characteristics and improved mechanical strength in boundary regions, preventing cracking
Solution Approach 2:
The patent applies local quality by varying the Zn component content in different magnetic layers. The first magnetic layers have one Zn content level optimized for certain properties, while the second magnetic layers have a different Zn content level optimized for boundary strength and crack resistance, allowing each region to have the specific properties it needs
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 method allows for the production of multilayer inductors with improved inductance and dc bias characteristics at a lower cost, without cracking issues, by forming interdiffusion layers within the conductive pattern, which control the Curie point and permeability effectively.
Implementation Method 1
a firing step of firing the laminate to induce interdiffusion of a constituent of the magnetic layer and a constituent of the nonmagnetic sheet, thereby forming an interdiffusion layer, which serves as a magnetic body
Implementation Method 2
the magnetic layer forming step comprises forming the magnetic layer containing a nickel (Ni) component, on the nonmagnetic sheet containing a zinc (Zn) component, and the firing step comprises inducing interdiffusion of the Ni component in the magnetic layer and the Zn component in the nonmagnetic sheet. The Curie point of a magnetic body can be controlled by a content of the Zn component.
Data Source
AI summary
A method of A production method including interdiffusion of a Ni component in a magnetic layer and a Zn component in a nonmagnetic sheet to form an interdiffusion layer in a region of the nonmagnetic sheet inside a conductive pattern. This method allows the interdiffusion layer to be formed without need for complicated processing of the nonmagnetic sheet. Furthermore, there is no boundary region between the magnetic layer and the nonmagnetic sheet around it. The nonmagnetic layer is located between turns of a coiled conductor to suppress degradation of dc bias characteristics and a magnetic body penetrates in a region inside the coiled conductor to suppress reduction in inductance due to provision of the nonmagnetic layer between turns of the coiled conductor.