Spinel Ferrite Coating on Metal for Thick Insulating Magnetic Composites
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ferrite-based composite materials for electromagnetic wave absorption and inductor applications face limitations in magnetic properties, thickness, adhesion, and electrical insulation due to high resin content, difficulty in forming thick films, and peeling issues, as well as limitations in applications requiring electric insulation.
Innovation Solution
A magnetic composite with a metal base material and a dense, polycrystalline spinel-type ferrite layer of specific thickness and composition, optimized for high magnetic and electrical properties, and improved adhesion, using an aerosol deposition method to achieve a thick, uniform ferrite layer with controlled crystalline state and surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ferrite powder and binder resin are used to form a composite material for electromagnetic wave absorption, then electromagnetic wave absorption performance is improved, but magnetic properties deteriorate due to high resin content
Solution Approach 1:
The invention changes the fundamental parameter of the binder material from organic resin to inorganic glass ceramic, which fundamentally alters the composition stability and magnetic properties while maintaining electromagnetic wave absorption performance through controlled glass ceramic formulation
Solution Approach 2:
The invention creates a composite material system combining ferrite powder with glass ceramic binder, where the glass ceramic phase provides both binding functionality and magnetic properties, resolving the contradiction between absorption performance and magnetic stability
2Reliability
If physical vapor deposition methods are used to form ferrite thin film on substrate, then electromagnetic wave absorption properties are improved, but film thickness is limited and manufacturing complexity increases
Solution Approach 1:
The invention replaces physical vapor deposition methods with screen printing technology, substituting a complex physical deposition process with a simpler mechanical printing method that enables thick film formation without equipment complexity
Solution Approach 2:
The invention changes the deposition mechanism from vapor-phase physical deposition to paste-based mechanical deposition, allowing film thickness to be controlled by paste application and firing parameters rather than deposition time and power
3Reliability
If ferrite layer is made thick to improve electromagnetic wave absorption, then absorption performance is improved, but adhesion to substrate deteriorates and peeling occurs
Solution Approach 1:
The invention creates a composite glass ceramic-ferrite system where the glass ceramic matrix provides strong adhesion to the substrate while embedding ferrite particles, enabling thick film formation without peeling through integrated bonding
Solution Approach 2:
The invention changes the binder material properties from organic resin to glass ceramic, which provides superior thermal stability and adhesion strength, allowing thick ferrite layers to be formed without peeling issues
4Stability of the object's composition
If conductive metal magnetic material is used in composite, then magnetic properties are improved, but electrical insulation capability deteriorates
Solution Approach 1:
The invention changes the magnetic material from conductive metal to non-conductive glass ceramic containing ferrite particles, fundamentally altering the electrical conductivity parameter while maintaining magnetic properties through the ferrite phase
Solution Approach 2:
The invention creates a composite where glass ceramic provides electrical insulation and ferrite particles provide magnetic properties, separating the functions of conductivity and magnetism to achieve both insulation capability and magnetic performance
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 magnetic composite exhibits excellent magnetic properties, electrical insulation, and adhesion, enabling applications in electromagnetic wave absorption, inductors, and other electronic components with enhanced performance and reliability.
Implementation Method 1
a material exhibiting magnetic loss is used. As a material exhibiting magnetic loss, ferrite having high permeability and high electric resistance is frequently used. The ferrite causes a resonance phenomenon at a specific frequency to absorb an electromagnetic wave, converts absorbed electromagnetic wave energy into thermal energy, and radiates the thermal energy to an outside.
Implementation Method 2
a composite magnetic film having an electromagnetic wave absorption function, which includes a magnetic phase constituting of a metal magnetic material and a high electric resistance phase of high insulating ferrite dispersed in an island shape in the magnetic phase (claim 1 in Patent Literature 3). In addition, Patent Literature 3 discloses that the composite magnetic film is formed by an aerosol deposition (AD) method in which raw material fine particle powder is aerosolized, and is caused to collide with a substrate or the like which is a film-forming material to form a thick film
Data Source
AI summary
A magnetic composite includes a metal base material and a ferrite layer provided on a surface of the metal base material, the metal base material has a thickness of 0.001 μm or more, and the ferrite layer has a thickness of 2.0 μm or more, contains spinel-type ferrite as a principal component, and has a ratio of 0.00 or more and 0.03 or less, the ratio being of an integrated intensity of a (222) plane to an integrated intensity of a (311) plane in X-ray diffraction analysis.