Soft Magnetic Compound With SiO2 Coating for Heat-Humidity Strength
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Solution Overview
Problem
Existing compounds containing soft magnetic powders suffer from a trade-off between soft magnetic characteristics and electrical insulating properties, with mechanical strength often deteriorating under high-temperature and humidity conditions.
Innovation Solution
A compound comprising first and second soft magnetic powders with different particle sizes, where the first powder is coated with an insulating film containing SiO2 and limited Fe2O3, and a thermosetting resin, enhancing both magnetic and insulating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the content of soft magnetic powder is increased to improve soft magnetic characteristics, then the soft magnetic characteristics increase, but the mechanical strength decreases under high-temperature and humidity environment
Solution Approach 1:
The patent uses the thermosetting resin as an intermediary material between the soft magnetic powder particles. This resin matrix provides mechanical strength and structural support, especially under high-temperature and humidity conditions, while allowing the soft magnetic powder to maintain its magnetic properties. The insulating coating film also acts as an intermediary protective layer that prevents direct contact between particles, reducing degradation under harsh environmental conditions.
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 compound achieves improved soft magnetic characteristics, electrical insulating properties, and mechanical strength, even at high filler content, by optimizing the coating and resin composition.
Implementation Method 1
the insulating coating film contains SiO2... the compound achieves improved soft magnetic characteristics, electrical insulating properties
Implementation Method 2
the resin composition contains a thermosetting resin... a compound containing: a first soft magnetic powder; a second soft magnetic powder; and a resin composition
Implementation Method 3
a content of Fe2O3 in a surface region of the first soft magnetic particles where a depth from an outermost surface of the first soft magnetic particles is 100 nm or less is 0% by atom or more and 10% by atom or less
Data Source
AI summary
A compound contains a first soft magnetic powder, a second soft magnetic powder, and a resin composition. The resin composition contains a thermosetting resin. The particle diameter of the first soft magnetic powder is greater than the particle diameter of the second soft magnetic powder. First soft magnetic particles composing the first soft magnetic powder include a metal portion, and an insulating coating film directly covering the metal portion. At least a part of the metal portion is a soft magnetic alloy containing Fe, Cr, and Si. The insulating coating film contains SiO2. The content of Fe2O3 is 0% by atom or more and 10% by atom or less in a surface region of the first soft magnetic particles where a depth from the outermost surface of the first soft magnetic particles is 100 nm or less.