Alloy Strip Lamination with Pre-Cracking for Stable Magnetic Sheets
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Solution Overview
Problem
Existing methods for dividing alloy strips into small pieces for magnetic sheets in wireless charging devices face challenges in maintaining consistent magnetic permeability due to the elasticity of resin films, leading to surface roughness and time-dependent changes in magnetic properties.
Innovation Solution
A method involving direct application of external force to alloy strips with adhesive layers and peelable release or protective films to form cracks, followed by laminating these strips to create an alloy strip laminate with alternating adhesive and cracked alloy layers, reducing the required force and improving the plane state of the strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external force is applied through a resin film to divide alloy strip into small pieces, then the alloy strip can be divided, but surface roughness occurs and magnetic properties change over time
Solution Approach 1:
The alloy strip is divided into small pieces by applying external force before lamination with the adhesive layer. This preliminary division action eliminates the need for subsequent division steps that would cause surface roughness, as the strip is already divided when bonded to the adhesive layer.
Solution Approach 2:
An adhesive layer is introduced as an intermediary between the divided alloy strip pieces and the magnetic sheet structure. This adhesive layer holds the divided pieces in place without requiring additional force application that would cause surface deformation, thus maintaining surface plane state while achieving the desired division.
2Ease of manufacture
If external force is applied to divide alloy strip, then division is achieved, but magnetic permeability becomes inconsistent
Solution Approach 1:
The alloy strip is divided into small pieces by applying external force before lamination with the adhesive layer. This preliminary division action eliminates the need for subsequent division steps that would cause surface roughness, as the strip is already divided when bonded to the adhesive layer.
Solution Approach 2:
An adhesive layer is introduced as an intermediary between the divided alloy strip pieces and the magnetic sheet structure. This adhesive layer holds the divided pieces in place without requiring additional force application that would cause surface deformation, thus maintaining surface plane state while achieving the desired division.
3Loss of energy
If alloy strip is divided into small pieces, then eddy current loss is reduced, but surface roughness and time-dependent magnetic property changes occur
Solution Approach 1:
The alloy strip is divided into small pieces by applying external force before lamination with the adhesive layer. This preliminary division action eliminates the need for subsequent division steps that would cause surface roughness, as the strip is already divided when bonded to the adhesive layer.
Solution Approach 2:
An adhesive layer is introduced as an intermediary between the divided alloy strip pieces and the magnetic sheet structure. This adhesive layer holds the divided pieces in place without requiring additional force application that would cause surface deformation, thus maintaining surface plane state while achieving the desired division.
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
This approach results in an alloy strip laminate with reduced surface roughness and minimized time-dependent changes in magnetic properties, ensuring consistent performance and superior characteristics for magnetic sheets.
Implementation Method 1
a step of dividing an alloy strip into small pieces by applying external force to the alloy strip
Implementation Method 2
forming a crack in the alloy strip to prepare a first laminate including the adhesive layer and the alloy strip with the crack formed
Implementation Method 3
forming a magnetic sheet including a step of forming a laminate sheet by sticking a protective film and a double-faced adhesive tape provided with a release film on its exposed surfaces to both sides of a thin film magnetic sheet
Implementation Method 4
the magnetic flux generated in the primary transmission coil of the power supply device generates an electromotive force in the secondary transmission coil of the power receiving device
Implementation Method 5
charging is performed by electric power transmission utilizing electromagnetic induction
Implementation Method 6
The magnetic sheet can suppress this heat generation in its role as a magnetic shielding material
Implementation Method 7
when a leakage flux generated during a wireless charging operation of a wireless charging device flows into another component such as a metal member configuring a secondary battery, the component generates heat due to an eddy current
Data Source
AI summary
This disclosure provides a method of producing an alloy strip laminate including applying an external force directly to an alloy strip of a first laminate member having an adhesive layer and the alloy strip, to form a crack in the alloy strip and prepare a first laminate including the adhesive layer and the cracked alloy strip, applying an external force directly to an alloy strip of a second laminate member having an adhesive layer and the alloy strip, to form a crack in the alloy strip and prepare at least one second laminate including the adhesive layer and the cracked alloy strip, and laminating the at least one second laminate on the first laminate to prepare an alloy strip laminate in which the adhesive layer, and the alloy strip with the crack formed are alternately layered; and a production apparatus for an alloy strip laminate.