Multi-Layer Oxide Metal Magnetic Particles for Stable Insulation
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Solution Overview
Problem
Existing methods for improving insulation properties of metal magnetic particles, such as coating with glass or forming oxide layers, face challenges like non-uniform film formation, dielectric breakdown, and insufficient insulation reliability, particularly when high-temperature heat treatment is required to prevent oxidation.
Innovation Solution
A metal magnetic particle with a multi-layer oxide structure comprising a first, second, and third oxide layer, where each layer has distinct Fe and Si content profiles, formed by mixing Si and Fe oxide films with Si alkoxide and alcohol, followed by hydrolysis, drying, and heat treatment in an oxidizing atmosphere, achieving improved insulation and direct-current superposition characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single insulating film is formed on metal magnetic particles, then insulation properties are improved, but film uniformity deteriorates and dielectric breakdown occurs
Solution Approach 1:
The patent divides a single insulating film into multiple layers with different compositions and functions. The first layer (SiO2-rich) provides uniform base insulation, the second layer (FeSiO3-rich) enhances adhesion and provides intermediate insulation, and the third layer (SiO2-rich) restores surface insulation properties. This segmentation resolves the contradiction by achieving both film uniformity and high insulation reliability through layered structure.
Solution Approach 2:
The patent uses composite material structure combining different oxide layers (SiO2, FeSiO3, Fe2O3) with distinct properties. Each layer contributes different functional characteristics: SiO2 layers provide high insulation resistance and uniformity, while FeSiO3 layer provides adhesion and intermediate properties. The composite structure achieves both film uniformity and superior insulation reliability that single-material films cannot provide.
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 multi-layer oxide structure enhances insulation resistance and direct-current superposition characteristics, providing a metal magnetic particle and inductor with high withstand voltage and improved magnetic permeability while maintaining magnetic properties.
Implementation Method 1
forming a coating film forming particle formed with a coating film containing silicon oxide by hydrolyzing and drying the Si alkoxide
Implementation Method 2
forming an oxide layer on the surface of the alloy particle by performing heat treatment on the coating film forming particle in an oxidizing atmosphere
Implementation Method 3
performing heat treatment on the coating film forming particle in an oxidizing atmosphere
Data Source
AI summary
A metal magnetic particle provided with an oxide layer on a surface of an alloy particle containing Fe and Si. The oxide layer has a first oxide layer, a second oxide layer, and a third oxide layer from a side of the alloy particle. All of the first oxide layer, the second oxide layer, and the third oxide layer contain Si. Also, in line analysis of element content by using a scanning transmission electron microscope-energy dispersive X-ray spectroscopy, the first oxide layer is a layer having Fe content smaller than Si content in the alloy particle, the second oxide layer is a layer having Fe content larger than the Si content in the alloy particle, and the third oxide layer is a layer having Fe content smaller than the Si content in the alloy particle.