Soft Magnetic Amorphous Alloy Ribbon Resin Layer Stress Management
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Solution Overview
Problem
The existing magnetic pieces with adhesive agents for multilayer structures experience a reduction in magnetic flux density due to compressive stress caused by the curing of the adhesive, leading to increased noise in AC cores, as the adhesive's thermal expansion coefficient differs from that of the amorphous alloy ribbon.
Innovation Solution
A magnetic piece with a resin layer having a Shore D hardness not exceeding 60 is applied to the soft magnetic amorphous alloy ribbon, using a resin with a Shore D hardness between 1 and 60, preferably containing polyester and polystyrene, to minimize stress and maintain high magnetic flux density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an adhesive agent is used to stack amorphous alloy ribbons into a multilayer structure, then the handleability and structural integrity are improved, but the magnetic flux density is reduced due to compressive stress from thermal expansion mismatch
Solution Approach 1:
The patent changes the physical and chemical parameters of the resin material, specifically selecting resins with Shore D hardness of 80 or less and glass transition temperature of 100°C or less. These parameter changes allow the resin to maintain flexibility and reduce compressive stress on the magnetic ribbons, preserving magnetic flux density while providing adequate adhesion for handleability.
Solution Approach 2:
The patent applies different resin materials with specific properties to different locations or functions within the multilayer structure. The resin serves dual functions: providing adhesion between layers while simultaneously acting as a stress-buffering layer. This local quality differentiation resolves the contradiction by optimizing each function's contribution.
2Strength
If a hard resin is used for the resin layer, then the adhesion strength is improved, but the magnetic flux density is reduced due to increased compressive stress
Solution Approach 1:
The patent identifies and controls critical parameters of the resin material, specifically Shore D hardness (≤80) and glass transition temperature (≤100°C). By optimizing these parameters, the resin achieves sufficient adhesion strength for structural integrity while maintaining softness to minimize compressive stress on the magnetic ribbons, thus preserving magnetic flux density.
Solution Approach 2:
The patent employs composite material design by combining resin with specific polymer compositions (such as polyesters, polyolefins, or their copolymers) that inherently possess the required balance of adhesion and softness. This composite approach allows simultaneous achievement of adhesion strength and stress reduction.
3Reliability
If a soft resin is used for the resin layer, then the magnetic flux density is maintained, but the adhesion strength and handleability are reduced
Solution Approach 1:
The patent optimizes resin parameters within specific ranges: Shore D hardness of 80 or less and glass transition temperature of 100°C or less. These parameter settings ensure the resin remains soft enough to maintain magnetic flux density while providing sufficient adhesion strength for practical handleability and structural integrity.
4Strength
If the resin layer thickness is increased, then the adhesion and stress buffering are improved, but the magnetic flux density is reduced
Solution Approach 1:
The patent optimizes the thickness parameter of the resin layer, specifying it should be 1 μm or more but 10 μm or less. This controlled thickness ensures sufficient adhesion and stress buffering capacity while minimizing the non-magnetic material volume that would otherwise reduce the overall magnetic flux density of the multilayer structure.
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 maintains a magnetic flux density of at least 90% of that without the resin layer, reducing core loss and noise, while ensuring sufficient adhesion and handleability.
Implementation Method 1
a resin whose Shore D hardness is not more than 60 is used for the resin layer
Implementation Method 2
applying an adhesive agent onto at least one surface of the soft magnetic amorphous alloy ribbon
Data Source
AI summary
A magnetic piece, a multilayer magnetic piece and a multilayer core with an adhesive agent of excellent saturation magnetic flux density are provided. The magnetic piece includes a soft magnetic amorphous alloy ribbon 1 and a resin layer 2 provided on at least one surface of the soft magnetic amorphous alloy ribbon. The resin layer contains a resin whose Shore D hardness is not more than 60. The resin may have a Shore D hardness of not more than 25 or may have a Shore D hardness of not less than 1.