NiZn Ferrite Multilayer Inductor Copper Electrode Sintering
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Solution Overview
Problem
The high cost and price volatility of silver, combined with the oxidation issues of copper, make it challenging to develop cost-effective and efficient internal conductors for multilayer type coil components, which affects the inductance and thermal characteristics of these products.
Innovation Solution
A magnetic layer composition using NiZn ferrite with a specific composition and structure, excluding copper, and employing a copper internal electrode with a shrinkage inhibitor, sintered under controlled oxidizing and reducing ambience to lower the sintering temperature and prevent oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If silver is used as an internal electrode, then electrical conductivity is improved, but material cost increases significantly
Solution Approach 1:
The patent replaces expensive silver with copper, which is a cheaper alternative material. Although copper has lower conductivity than silver, it provides sufficient electrical performance for the application while dramatically reducing material costs. This substitution follows the principle of using cheaper materials that meet the functional requirements without sacrificing essential performance.
Solution Approach 2:
The patent modifies the sintering process parameters, specifically conducting sintering in a reducing atmosphere (nitrogen or hydrogen environment) at controlled temperatures. This parameter change prevents copper oxidation during the sintering process, enabling the use of copper as an internal electrode material while maintaining its electrical conductivity and structural integrity.
2Quantity of substance
If copper is used as an internal electrode, then material cost is reduced, but oxidation resistance deteriorates
Solution Approach 1:
The patent employs a reducing atmosphere (inert environment) during the sintering process, using nitrogen or hydrogen gas to prevent copper oxidation. This creates a protective environment that eliminates oxygen contact during the critical sintering stage, ensuring the copper internal electrode maintains its metallic state and electrical properties without forming oxides that would degrade performance.
Solution Approach 2:
The patent controls the sintering temperature and atmosphere parameters to prevent copper oxidation. By conducting sintering in a reducing atmosphere at appropriately controlled temperatures, the process maintains copper in its metallic state while still achieving the necessary densification and bonding of the ferrite body, thus resolving the oxidation resistance issue.
3Stability of the object's composition
If NiCuZn ferrite is used as a magnetic layer, then magnetic properties are improved, but resistance to reduction deteriorates
Solution Approach 1:
The patent removes copper (Cu) from the NiCuZn ferrite composition, creating a NiZn ferrite system instead. This extraction of the problematic copper element eliminates the reduction resistance issue while preserving the essential magnetic properties through the nickel-zinc ferrite structure. The modified composition maintains functional performance without the vulnerability to reduction.
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
Enables the use of copper as an internal electrode, reducing material costs and improving magnetic properties, while maintaining similar electric characteristics to conventional silver-based components.
Implementation Method 1
a magnetic layer composition including NiZn ferrite... sintered under controlled oxidizing and reducing ambience to lower the sintering temperature and prevent oxidation
Implementation Method 2
sintered under controlled oxidizing and reducing ambience to lower the sintering temperature and prevent oxidation
Implementation Method 3
sintered under controlled oxidizing and reducing ambience... prevent oxidation
Data Source
AI summary
Disclosed herein are a multilayer type inductor including a magnetic layer composition including NiZn ferrite, a multilayer type coil component including a magnetic layer prepared therefrom, and a method for manufacturing the same.According to the present invention, a copper electrode can be used as an internal electrode of a multilayer type coil product, by including NiZn ferrite in the magnetic layer. As copper is used for the internal electrode, material costs can be significantly reduced. Furthermore, the present invention can improve the maximum saturation magnetization value against the NiCuZn ferrite by about 10%, due to exclusion of Cu having weak magnetism, and can be more desirably used in a product employing high current.