Winding-Type Coil Component Core Mechanical Strength
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Solution Overview
Problem
The transition from ferritic to metallic magnetic materials in winding-type coil components leads to increased porosity, causing electrode material penetration and reduced mechanical strength, resulting in issues like chipping and cracking, especially in drum-type cores with flange parts.
Innovation Solution
A winding-type coil component is developed using a core made of soft magnetic alloy grains containing Fe, Si, and at least one of Cr and Al, with an oxide layer composed of Si and Cr/Al, where Si content exceeds the total Cr and Al content, bonded together to enhance mechanical strength and prevent penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If ferrous metal magnetic materials are used instead of ferritic materials to increase current capacity, then current capacity is improved, but mechanical strength deteriorates causing chipping and cracking
Solution Approach 1:
The core uses a composite structure combining ferrous metal magnetic material grains with a glassy phase matrix. The glassy phase acts as a binding material that holds the metal grains together, providing mechanical strength while the metal grains provide high current capacity. This composite approach allows simultaneous achievement of both high power and high strength.
Solution Approach 2:
The invention changes the physical and chemical parameters of the core material by controlling the glass transition temperature (Tg) of the glassy phase to be 50°C or higher, and adjusting the composition ratios of oxide components (SiO2: 30-70 wt%, B2O3: 5-30 wt%, Al2O3: 5-30 wt%). These parameter changes optimize both mechanical strength and electrical insulation properties while maintaining high current capacity.
2Power
If ferrous metal magnetic materials are used instead of ferritic materials, then current capacity is improved, but electrode material penetration increases
Solution Approach 1:
The glassy phase serves as an intermediary layer between the electrode material and the ferrous metal magnetic material grains. This glassy matrix prevents direct contact and penetration of electrode material into the metal grains, while still allowing electrical connection. The glassy phase with Tg≥50°C provides effective barrier properties against electrode penetration.
Solution Approach 2:
The glassy phase creates an inert environment around the ferrous metal grains, preventing chemical reactions and penetration between the electrode paste and the reactive metal magnetic material. The glass composition (rich in SiO2, B2O3, Al2O3) provides chemical inertness that protects the metal grains from electrode material infiltration.
3Ease of operation
If drum-type core with flange parts is used for winding, then coil winding is enabled, but cracking and chipping occur due to reduced strength
Solution Approach 1:
The flange parts are formed as composite structures with ferrous metal magnetic material grains embedded in a glassy phase matrix. The glassy phase provides continuous bonding between grains, creating a strong composite material that can withstand the mechanical stresses of coil winding operations while maintaining the drum-type geometry with flanges.
Solution Approach 2:
By controlling the glass transition temperature to be 50°C or higher and optimizing the oxide composition ratios, the flange parts achieve enhanced mechanical strength and fracture resistance. These parameter changes ensure the flange parts can withstand bending and mounting stresses during coil winding and circuit board assembly without cracking or chipping.
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 provides a winding-type coil component with improved mechanical strength, preventing cracking and chipping, and maintaining high magnetic permeability, enabling efficient handling and mounting on circuit boards while supporting size reduction and increased current capacity.
Implementation Method 1
an oxide layer which is formed around the soft magnetic alloy grains to bond the soft magnetic alloy grains together
Data Source
AI summary
A winding-type coil component whose core member is constituted by: soft magnetic alloy grains 210 containing Fe, Si, and at least one of Cr and Al, as constituent elements; and an oxide layer 220 which is formed around the soft magnetic alloy grains to bond the soft magnetic alloy grains together and contains Si, as well as at least one of Cr and Al, as constituent elements, and whose content of Si based on mass is higher than the total content of Cr and Al. The winding-type coil component has high mechanical strength.