Multilayer Inductor Composition for Low-Temperature Sintering

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Solution Overview

Problem

Conventional multilayer power inductors made of iron alloy have moderate magnetic permeability and high iron loss, leading to deteriorated conversion efficiency in DC-DC converters, and require high sintering temperatures above 700°C, which is inefficient for modern electronic devices.

Innovation Solution

A mixture comprising low iron loss amorphous or nanocrystalline magnetic powders with a glass material, sintered at a temperature not exceeding 470°C, using a coating process to enhance insulation and bonding strength, allowing for lower temperature formation of multilayer inductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional iron alloy is used for multilayer power inductor, then the inductor can be manufactured with moderate magnetic permeability, but the iron loss is high which deteriorates conversion efficiency

Engineering Contradiction:

Improveiron lossVSAvoidconversion efficiency

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent changes the material parameters by using amorphous or nanocrystalline magnetic powder instead of conventional iron alloy. This fundamental material parameter change reduces iron loss significantly while maintaining the required magnetic properties, thereby improving conversion efficiency in DC-DC converters

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining amorphous or nanocrystalline magnetic powder with glass material and binder. This composite structure achieves both low iron loss and high conversion efficiency by leveraging the superior magnetic properties of amorphous/nanocrystalline phases while using glass material for insulation and structural integrity

Inventive Principle:

Principle #40Composite materials

2Temperature

If conventional sintering method with atomized silver is used, then higher density and lower resistivity can be achieved, but the sintering temperature must be above 700°C

Engineering Contradiction:

Improvesintering temperatureVSAvoidmanufacturing process

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent fundamentally changes the sintering temperature parameter from above 700°C to below 470°C by replacing the conventional atomized silver sintering method with a new low-temperature sintering process using glass material as the bonding agent, making the manufacturing process more suitable for modern electronic devices

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces glass material as an intermediary bonding agent that enables sintering at low temperatures. The glass material acts as a flux that facilitates bonding between magnetic powder particles at temperatures below 470°C, replacing the need for high-temperature atomized silver sintering

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If high sintering temperature above 700°C is used to achieve higher density and lower resistivity, then the inductor performance is improved, but the manufacturing complexity and energy consumption increase

Engineering Contradiction:

Improvedensity controlVSAvoidsintering energy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by stationary object

Solution Approach 1:

The patent changes the sintering temperature parameter from above 700°C to below 470°C while maintaining adequate density control. This parameter change reduces sintering energy consumption significantly while achieving the required manufacturing precision through the low-temperature sintering process with glass material

Inventive Principle:

Principle #35Parameter changes

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

Improves conversion efficiency of DC-DC converters by reducing iron loss and enabling lower temperature sintering, suitable for modern electronic devices with thinner designs.

Implementation Method 1

a softening point temperature of the glass material is in a range of 300° ̃430° C.

Methodology Applied

Scientific EffectSoftening: Melting

Implementation Method 2

The conventional multilayer power inductor is sintered with atomized silver as the inner circuit, and the sintering temperature needs to be above 700° C. to achieve the effect of higher density and lower resistivity.

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS20250312845A1Mixture for forming a multilayer inductor and the fabrication method thereof

Publication Date: 2025.10.09 CYNTEC

AI summary

A mixture for making a multilayer inductor, wherein the mixture comprises a first magnetic powder, a second magnetic powder, and a glass material, wherein each of the first magnetic powder and the second magnetic powder comprises an amorphous or nanocrystalline magnetic powder, wherein a softening point temperature of the glass material is in a range of 300°˜430° C.