Method of making a multilayer monolithic magnet component

A method for constructing a solid composite magnetic component comprising the steps of:

• preparing a magnetic material in a ceramic tape format having a first sintering rate and a first sintering temperature;
• preparing an insulating non-magnetic material in a ceramic material format, with a sintering rate and sintering temperature substantially identical to the first sintering rate and first sintering temperature;
• including apertures in the magnetic material for accepting the insulating non-magnetic material;
• depositing conductors on and through the insulating non-magnetic material to form at least a winding to magnetically engage the magnetic material;
• forming a structure by successive layering of the magnetic material and the insulating non-magnetic material and further adding the insulating non-magnetic material to the apertures to form a structure with well defined magnetic and insulating non-magnetic regions;
• applying pressure to laminate the formed structure;
• and
• co-firing the laminated structure to form a solid composite structure.

A process for producing a solid composite magnetic component comprising at least two different materials each comprised of a ferrite matrix;

• wherein the ferrite materials are of the form M.sub.1+x Fe.sub.2-y O.sub.4-z
• comprising the steps of:
• preparing a magnetic material by;
• providing a first ferrite powder of a substantially MnZn ferrite composition suitable to provide a relatively high permeability in a resulting first ferrite matrix,
• preparing an insulating non-magnetic material by;
• providing a second ferrite powder of a substantially Ni ferrite composition suitable to provide a high resistivity and a low permeability in a resulting second ferrite matrix, adding a Cu oxide to the second ferrite powder in an amount ranging from 1% mol to 10% mol of the total amount of the second ferrite powder so that the second ferrite powder has a sintering rate and sintering temperature substantially identical to that of the first ferrite powder,
• admixing the first ferrite powder with an organic binding material and forming the resulting mixture into a first ceramic tape,
• admixing the second ferrite powder with an organic binding material and forming the resulting mixture into a second ceramic tape,
• defining different tape layers with specified first tape layers having certain defined apertures;
• forming a layered structure with the different first and second ceramic tape layers in which the first tape layers include a geometric structure suitable for a magnetic core and in which the apertures are filled with an insulating non-magnetic material comprising the second ferrite powder;
• laminating the layered structure by applying a pressure thereto,
• firing the laminated structure;
• sintering the resulting structure at a temperature exceeding 800.degree. centigrade to produce a sintered product having two ferrite matrix materials in a single composite structure;
• cooling the single composite structure to form the solid composite magnetic component.

A method for constructing a solid composite magnetic component with multilayer ceramic tape layers;

• comprising the steps of:
• providing a first ferrite powder of a MnZn ferrite composition having a specific sintering rate and temperature;
• providing a second ferrite powder of a Ni ferrite composition and further doped with copper oxide particles in an amount equaling 1-10% of the overall molar composition to introduce a liquid phase into the second ferrite material to lower its sintering temperature and modify its sintering rate so that they equal the specific sintering rate and temperature;
• preparing a magnetic material in the form of a ceramic tape comprising a binder and the first ferrite powder of a MnZn ferrite composition;
• preparing an insulating non-magnetic material comprising a binder and the second ferrite powder of a Ni ferrite composition;
• forming apertures in the magnetic material for accepting the insulating non-magnetic material;
• placing pluralities of the magnetic materials formed of ceramic tape adjacent each other at least in part in layers and inserting the insulating non-magnetic material in the apertures to assemble a multilayer structure having well defined regions of high permeability and well defined regions of low permeability adjacent the regions of high permeability;
• and
• applying pressure to the laminate the multilayer structure;
• co-firing the laminate structure to a temperature within a range of 800.degree. to 1400.degree. degrees Centigrade to join the layers into a solid composite structure.

A method for constructing a solid composite structure including at least a magnetic component comprising the steps of:

• preparing a magnetic material in a ceramic tape format having a first sintering rate and a first sintering temperature;
• preparing an insulating non-magnetic ceramic material, with a sintering rate and sintering temperature substantially identical to the first sintering rate and first sintering temperature;
• forming a structure by successive layering of the magnetic material and combining it with the insulating non-magnetic material to form a first structure with well defined magnetic and non-magnetic regions;
• printing conductors on a portion of the structure so as to magnetically engage the magnetic material;
• applying pressure to laminate the structure;
• and
• co-firing the first structure to form a solid composite structure.

A method for constructing a solid composite structure including at least a magnetic component comprising the steps of:

• preparing a magnetic ceramic material having a first sintering rate and a first sintering temperature:
• preparing an insulating non-magnetic material with a sintering rate and sintering temperature substantially identical to the first sintering rate and first sintering temperature;
• forming a structure by successive layering of layers, each layer containing at least one of the magnetic ceramic material and the insulating non-magnetic material to form a first structure with well defined magnetic and non-magnetic regions;
• constructing conductors within a portion of the structure so that a current in the conductors is magnetically coupled with the magnetic material;
• applying pressure to laminate the structure;
• and
• co-firing the structure to form a solid composite structure.