Composite magnetic powder

Abstract

The utility model discloses composite magnetic powder. The composite magnetic powder comprises magnetic powder, a thermosetting resin layer and a thermoplastic resin layer. The thermosetting resin layer coats the magnetic powder, and the thermoplastic resin layer coats the thermosetting resin layer. According to the utility model, the carbon neutralization and high compression ratio of the composite magnetic powder can be realized.

Description

Technical Field

[0001] This utility model relates to a composite magnetic powder, and more particularly to a composite magnetic powder used for manufacturing inductor cores. Background Technology

[0002] An inductor is a passive electronic component widely used in various electronic circuits. Therefore, as electronic products become smaller, the smaller the inductor, the better. An inductor typically consists of a magnetic core and leads. To reduce the size of the inductor, a high-density magnetic core is made using iron powder.

[0003] However, when making magnetic cores from iron powder, the cores are susceptible to corrosion due to iron's tendency to rust. Current technology involves spraying an anti-corrosion material onto the surface after the inductor is formed; however, this process not only increases the number of steps and costs, but also raises environmental concerns regarding solvent handling.

[0004] Therefore, how to achieve carbon neutralization and high compression ratio of composite magnetic powder through structural design improvements to overcome the above-mentioned defects has become one of the important issues that this project aims to solve. Utility Model Content

[0005] The technical problem to be solved by this utility model is to provide a composite magnetic powder that addresses the shortcomings of the existing technology.

[0006] To solve the above-mentioned technical problems, one of the technical solutions adopted by this utility model is to provide a composite magnetic powder, which includes: magnetic powder, a thermosetting resin layer coating the magnetic powder, and a thermoplastic resin layer coating the thermosetting resin layer.

[0007] Furthermore, the composite magnetic powder also includes a coupling agent layer directly formed on the magnetic powder.

[0008] Furthermore, the composite magnetic powder further includes an oxide powder layer disposed between the coupling agent layer and the thermosetting resin layer.

[0009] Furthermore, the composite magnetic powder also includes a dispersant layer and a thermoplastic resin coating layer.

[0010] Furthermore, the composite magnetic powder also includes an oxide metal layer and a coating dispersant layer.

[0011] Furthermore, the composite magnetic powder also includes a lubricant layer and a metal oxide coating layer.

[0012] One of the beneficial effects of this utility model is that the wound solid electrolytic capacitor packaging structure and manufacturing method provided by this utility model can improve the high compression ratio of the magnetic powder through the technical solutions of "the thermosetting resin layer coating the magnetic powder" and "the thermoplastic resin layer coating the thermosetting resin layer".

[0013] To further understand the features and technical content of this utility model, please refer to the following detailed description and drawings of this utility model. However, the drawings provided are for reference and illustration only and are not intended to limit this utility model. Attached Figure Description

[0014] Figure 1 This is a perspective view of the first embodiment of the present utility model.

[0015] Figure 2 This is a perspective view of the second embodiment of the present utility model.

[0016] Figure 3 This is a perspective view of the third embodiment of the present utility model.

[0017] Figure 4 This is a perspective view of the fourth embodiment of the present utility model.

[0018] Figure 5 This is a three-dimensional schematic diagram of the fifth embodiment of the present utility model.

[0019] Figure 6 This is a perspective view of the sixth embodiment of the present utility model.

[0020] Figure reference numerals: 1A-1F: composite magnetic powder; 11: magnetic powder; 12: thermosetting resin layer; 13: thermoplastic resin layer; 14: coupling agent layer; 15: oxide powder layer; 16: dispersant layer; 17: metal oxide layer; 18: lubricant layer. Detailed Implementation

[0021] The following specific embodiments illustrate the implementation of the "composite magnetic powder" disclosed in this utility model. Those skilled in the art can understand the advantages and effects of this utility model from the content disclosed in this specification. This utility model can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of this utility model. Furthermore, the accompanying drawings of this utility model are for simple illustrative purposes only and are not depictions of actual dimensions, as stated in advance. The following embodiments will further describe the relevant technical content of this utility model in detail, but the disclosed content is not intended to limit the scope of protection of this utility model. Additionally, the term "or" as used herein may include, depending on the actual situation, any combination of any one or more of the associated listed items.

[0022] First Embodiment

[0023] See Figure 1 As shown, the first embodiment of this utility model provides a composite magnetic powder 1A, which includes: magnetic powder 11, a thermosetting resin layer 12, and a thermoplastic resin layer 13. The magnetic powder 11 can be iron powder, Fe-Cr-Si alloy, Fe-Si alloy, Fe-Al-Si alloy, Fe-Ni-Si alloy, Fe-Si-B alloy, Fe-Si-B-Cr alloy, Fe-Si-B-Cr alloy, Fe-Al-Cr alloy, Fe-Si-B-Nb-Cu alloy, Fe-Si-Cr-B-Nb-Cu alloy, and an amorphous alloy. In an optional embodiment of this utility model, the magnetic powder 11 can be iron powder, Fe-Cr-Si alloy, Fe-Si alloy, Fe-Al-Si alloy, and an amorphous alloy.

[0024] The thermosetting resin layer 12 is formed of silicone resin, such as methyl vinyl silicone resin or methyl phenyl vinyl silicone resin. However, the examples given above are merely one possible embodiment and are not intended to limit the present invention. Thermosetting silicone resins are viscous at room temperature, which facilitates the formation of the thermosetting resin layer 12 of the present invention. In this embodiment, the content of the thermosetting resin layer 12 is 0.5% to 1.7% of the total amount of composite magnetic powder 1A, for example, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, and 1.6%. If the content of the thermosetting resin layer 12 is less than 0.5%, the compressibility of the composite magnetic powder 1A will be poor. If the content of the thermosetting resin layer 12 is greater than 1.7%, the processing cost will increase.

[0025] In this embodiment, the thermoplastic resin layer 13 is formed of phenolic resin, which is obtained by the condensation reaction of phenolic compounds and aldehyde compounds. The content of the thermoplastic resin layer 13 is 0.4% to 1.3% of the total amount of composite magnetic powder 1A, for example, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, and 1.2%. If the content of the thermoplastic resin layer 13 is less than 0.4%, the corrosion resistance of the composite magnetic powder 1A is poor.

[0026] Second Embodiment

[0027] See Figure 2 As shown, the second embodiment of this utility model provides a composite magnetic powder 1B. This embodiment is largely the same as the first embodiment described above, and the differences are explained below.

[0028] In this embodiment, the composite magnetic powder 1B further includes a coupling agent layer 14, which is directly formed on and coats the magnetic powder 11. The coupling agent layer 14 is formed of at least one coupling agent selected from the group consisting of silane coupling agents, titanate coupling agents, aluminate coupling agents, and zirconate coupling agents. However, the above examples are merely one possible embodiment and are not intended to limit the present invention.

[0029] In this embodiment, to obtain suitable adhesion strength, the content of coupling agent layer 14 is 0.0001% to 0.01% of the total amount of composite magnetic powder 1B, for example, 0.0002%, 0.0004%, 0.0006%, 0.0008%, 0.001%, 0.002%, 0.004%, 0.006%, or 0.008%. If the content of coupling agent layer 14 is less than 0.0001%, the bonding effect between magnetic powder 11 and thermosetting resin layer 12 will be poor.

[0030] Third Embodiment

[0031] See Figure 3 As shown, the third embodiment of this utility model provides a composite magnetic powder 1C. This embodiment is largely the same as the aforementioned second embodiment, and the differences are explained below.

[0032] In this embodiment, the composite magnetic powder 1C further includes an oxide powder layer 15 disposed between the coupling agent layer 14 and the thermosetting resin layer 12. The oxide powder layer is formed from at least one oxide powder selected from the group consisting of silicon dioxide and titanium dioxide. However, the examples given above are merely one possible embodiment and are not intended to limit the present invention. Furthermore, the oxide powder layer 15 may be formed from nano-oxide powder.

[0033] In this embodiment, the content of oxide powder layer 15 is 0.007% to 0.04% of the total amount of composite magnetic powder 1C, for example, 0.008%, 0.009%, 0.001%, 0.002%, or 0.03%.

[0034] In an embodiment of this invention, the oxide powder layer 15 may be formed by first forming a layer of nano-silica and then forming another layer of nano-titanium dioxide. Specifically, the content of nano-silica is 0.005% to 0.01% of the total amount of composite magnetic powder 1C, and the content of nano-titanium dioxide is 0.002% to 0.03% of the total amount of composite magnetic powder 1C.

[0035] Fourth embodiment

[0036] See Figure 4 As shown, the fourth embodiment of this utility model provides a composite magnetic powder 1D. This embodiment is largely the same as the aforementioned third embodiment, with the differences described below. The composite magnetic powder 1D also includes surfactants such as sodium or ammonium polycarboxylate, acrylic acid, polyethylimide, phosphoric acid, aliphatic polycarboxylic acid ester, unsaturated fatty acid amine salt, and sorbitan monooleate, as well as polymer compounds such as polyester amine salt and polyamide.

[0037] In this embodiment, the composite magnetic powder 1D further includes a dispersant layer 16, which is formed on and covers the thermoplastic resin layer 13. Specifically, the dispersant layer 16 may be formed of at least one dispersant selected from the group consisting of polyester amine salts, polyamides, polyethylimides, aliphatic polycarboxylate esters, sorbitan monooleate, and unsaturated fatty acid amine salts. However, the examples given above are merely one possible embodiment and are not intended to limit the present invention.

[0038] In this embodiment, the content of the dispersant layer 16 is 0.001% to 0.1% of the total amount of the composite magnetic powder 1D, for example, 0.002%, 0.004%, 0.006%, 0.008%, 0.01%, 0.02%, 0.04%, 0.06%, or 0.08%.

[0039] Fifth Embodiment

[0040] See Figure 5 As shown, the fifth embodiment of this utility model provides a composite magnetic powder 1E. This embodiment is largely the same as the fourth embodiment described above, and the differences are explained below.

[0041] In this embodiment, the composite magnetic powder 1E further includes a metal oxide layer 17, which is formed on and covers the dispersant layer 16. Specifically, the metal oxide layer 17 may be formed of at least one metal oxide selected from the group consisting of aluminum oxide, zinc dioxide, nickel oxide, chromium oxide, manganese oxide, cobalt oxide, and magnesium oxide. However, the examples given above are merely one possible embodiment and are not intended to limit the present invention.

[0042] In this embodiment, the content of the metal oxide layer 17 is 0.005% to 0.01% of the total amount of composite magnetic powder 1E, for example, 0.006%, 0.007%, 0.008%, or 0.009%.

[0043] Sixth Embodiment

[0044] See Figure 6 As shown, the sixth embodiment of this utility model provides a composite magnetic powder 1F. This embodiment is largely the same as the fifth embodiment described above, and the differences are explained below.

[0045] The composite magnetic powder 1F also includes a lubricant layer 18, which is formed on and covers the metal oxide layer 17. Specifically, the lubricant layer 18 may be formed of at least one lubricant selected from the group consisting of zinc stearate, calcium stearate, lithium stearate, paraffin wax, synthetic polyethylene, stearyl alcohol, stearamide, oleamide, and erucamide. However, the examples given above are merely one possible embodiment and are not intended to limit the present invention.

[0046] In this embodiment, the content of the lubricant layer 18 is 0.001% to 0.005% of the total amount of composite magnetic powder 1F, for example, 0.002%, 0.003%, or 0.004%. A lubricant layer 18 content less than 0.001% will result in insufficient lubrication of the magnetic powder. If the lubricant layer 18 content is greater than 0.005%, it will lead to a higher porosity between the magnetic powder particles, making it impossible to obtain magnetic powder with a high compression ratio.

[0047] Beneficial effects of the embodiments

[0048] One of the beneficial effects of this utility model is that the wound solid electrolytic capacitor packaging structure and manufacturing method provided by this utility model can improve the high compression ratio of the magnetic powder through the technical solutions of "the thermosetting resin layer coating the magnetic powder" and "the thermoplastic resin layer coating the thermosetting resin layer".

[0049] Furthermore, because the composite magnetic powder of this invention features a technical solution where "the thermoplastic resin layer is formed of phenolic resin," the inductor manufactured using this composite magnetic powder exhibits excellent acid resistance and can pass salt spray tests without the need for anti-corrosion coating. Specifically, the inductor manufactured using the composite magnetic powder of this invention can pass a 24-hour rust prevention test in a salt spray environment at 35℃±2℃, a salt content of 5%±1%, and a pH of 6.5~7.2. In other words, the composite magnetic powder of this invention can achieve carbon neutralization, making it more environmentally friendly than inductors that require anti-corrosion coating.

[0050] The above-disclosed content is only a preferred and feasible embodiment of the present utility model, and is not intended to limit the scope of protection of the claims of the present utility model. Therefore, all equivalent technical changes made based on the content of the present utility model specification and drawings are included in the scope of protection of the claims of the present utility model.

Claims

1. A composite magnetic powder, characterized in that, The composite magnetic powder comprises: Magnetic powder; A thermosetting resin layer, wherein the thermosetting resin layer coats the magnetic powder; A thermoplastic resin layer, the thermoplastic resin layer covering the thermosetting resin layer; and A dispersant layer that coats the thermoplastic resin layer.

2. The composite magnetic powder according to claim 1, characterized in that, The composite magnetic powder further includes a coupling agent layer directly formed on the magnetic powder.

3. The composite magnetic powder according to claim 2, characterized in that, The composite magnetic powder further includes an oxide powder layer disposed between the coupling agent layer and the thermosetting resin layer.

4. The composite magnetic powder according to claim 1, characterized in that, The composite magnetic powder further includes a metal oxide layer that coats the dispersant layer.

5. The composite magnetic powder according to claim 4, characterized in that, The composite magnetic powder further includes a lubricant layer that coats the oxide metal layer.

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