Layered Oxide Magnetic Base Body for Particle Insulation
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Solution Overview
Problem
Existing magnetic base bodies with metal magnetic particles coated in insulating films face challenges in achieving both sufficient insulation and magnetic properties due to limitations in forming thin, uniform coating films, leading to degraded magnetic permeability.
Innovation Solution
A magnetic base body design with metal magnetic particles covered by multiple oxide films, where inner oxide films composed mainly of silica are thicker than outer oxide films composed of chromium or alumina, enhancing insulation properties while maintaining magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating coating films are applied to the surfaces of raw powder, then insulation between metal magnetic particles is improved, but magnetic properties (magnetic permeability) are degraded
Solution Approach 1:
The invention changes the parameters of the insulating film by using oxide films formed through oxidation of elements in the raw powder instead of applied coating films. The oxide films have different thickness and composition characteristics that improve both insulation and magnetic properties simultaneously
Solution Approach 2:
The invention uses composite oxide films containing multiple elements (Si, Cr, Al) that form layered structures on the metal magnetic particle surfaces. This composite structure provides both sufficient insulation and maintains magnetic permeability by combining the insulating properties of different oxide materials
2Reliability
If oxide films are formed on the surfaces of metal magnetic particles, then insulation is improved, but the oxide films are too thin to provide sufficient insulation
Solution Approach 1:
The invention creates a composite oxide film structure containing multiple elements where Si forms the base oxide layer and Cr or Al forms outer oxide layers. This composite structure achieves sufficient insulation thickness while maintaining magnetic properties through the combined characteristics of different oxide materials
Solution Approach 2:
The invention applies different oxide layers with different properties at different locations on the particle surface. The Si oxide provides the main insulating thickness while Cr or Al oxide layers provide additional protective qualities, creating a locally optimized structure that balances insulation and magnetic properties
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 improved insulation properties allow direct attachment of external electrodes to the base body without additional insulating films, enhancing the magnetic permeability and filling factor of the base body.
Implementation Method 1
the metal magnetic particles are produced by heating a soft magnetic alloy powder containing Fe, Si, and Cr at 750° C. Each has a first oxide film mainly composed of silica (SiO2) formed on the surface of the metal magnetic particle and a second oxide film mainly composed of chromium (III) oxide (Cr2O3) formed on the outer surface of the first oxide film
Data Source
AI summary
Provided is a magnetic base body having improved insulating properties of metal magnetic particles. A magnetic base body according to one embodiment includes: a plurality of metal magnetic particles containing Fe, Si, and an element a; first oxide films covering surfaces of the plurality of metal magnetic particles; and second oxide films covering surfaces of the first oxide films. The first oxide films are composed mainly of an oxide of Si. The second oxide films are composed mainly of an oxide of the element a. A first thickness indicating a thickness of the first oxide films is larger than a second thickness indicating a thickness of the second oxide films.