Powder Magnetic Core Binder Layer Thickness Optimization
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Solution Overview
Problem
Inductors used in electronic devices, such as personal computers, face challenges in achieving high inductance characteristics and low loss in high frequency ranges while maintaining a small size, as existing methods struggle to increase magnetic powder filling percentage while maintaining sufficient insulation between particles.
Innovation Solution
A powder magnetic core with a binder layer composed of low melting glass and resin, where the magnetic powder is coated with low melting glass and then granulated with a resin material, resulting in a core with 88% or more magnetic powder and a binder layer thickness of 20 nm or smaller, ensuring high insulation and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the magnetic powder filling percentage is increased to reduce size and improve inductance characteristics, then the inductor size is reduced and inductance characteristics are improved, but the insulation between particles deteriorates and loss increases
Solution Approach 1:
The patent changes the physical and chemical parameters of the binder layer by using low melting glass with specific composition (SiO2: 30-70 wt%, B2O3: 10-40 wt%, Al2O3: 5-20 wt%) and controlling its thickness to 20 nm or smaller. This parameter optimization allows achieving both high magnetic powder filling (88 vol% or more) and sufficient insulation, resolving the contradiction between increasing powder content and maintaining particle insulation.
Solution Approach 2:
The patent employs a composite binder layer combining low melting glass and resin material. The low melting glass provides insulation and bonding, while the resin material enhances the binding effect. This composite approach enables the binder layer to simultaneously achieve insulation function and strong adhesion even at ultra-thin thickness (≤20 nm), allowing high magnetic powder filling percentage without compromising insulation between particles.
2Quantity of substance
If the binder layer thickness is reduced to increase magnetic powder filling percentage, then the magnetic powder filling percentage is increased, but the insulation between particles deteriorates
Solution Approach 1:
The patent optimizes the binder layer thickness parameter to 20 nm or smaller while maintaining insulation function. By precisely controlling this dimensional parameter and combining it with low melting glass composition optimization, the patent achieves high magnetic powder filling (88 vol% or more) without sacrificing insulation performance.
Solution Approach 2:
The low melting glass acts as an intermediary substance between magnetic powder particles, providing insulation and bonding functions. Even at ultra-thin thickness (≤20 nm), the low melting glass maintains sufficient insulation properties while enabling high powder packing density, thus resolving the contradiction between thin binder layer and adequate insulation.
3Volume of moving object
If the inductor size is reduced for compact electronic devices, then the device size is reduced, but the inductance characteristics deteriorate under large current
Solution Approach 1:
The patent optimizes multiple parameters including magnetic powder filling percentage (88 vol% or more), binder layer thickness (≤20 nm), and low melting glass composition to achieve high inductance characteristics in a compact size. These parameter optimizations allow the inductor to maintain excellent performance under large current while keeping the device size reduced for compact electronic applications.
Solution Approach 2:
The composite structure of low melting glass and resin material in the binder layer enables the inductor to achieve high magnetic powder filling (88 vol% or more) in a compact volume, thereby maintaining high inductance characteristics under large current while keeping the overall inductor size reduced for modern electronic devices.
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 solution enables a low loss in high frequency ranges while reducing the size of the powder magnetic core and inductor, achieving high inductance characteristics even with large currents, by maintaining a high filling percentage of magnetic powder and ensuring sufficient insulation.
Implementation Method 1
a process of coating a magnetic powder with a low melting glass
Implementation Method 2
a process of hot forming the magnetic powder after the granulation
Data Source
AI summary
A powder magnetic core capable of achieving a low loss in a high frequency range while reducing the size thereof is provided. A powder magnetic core according to the present disclosure is a powder magnetic core in which a magnetic powder is bonded via a binder layer. The powder magnetic core contains 88 volume % or more of magnetic powder, and the percentage of parts of the binder layer having thicknesses of 20 nm or smaller in the binder layer that is present between particles of the magnetic powder is equal to or smaller than 6% (not including 0%).