Composite Ferrite Sheet Magnetic Shielding
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Solution Overview
Problem
Thinned ferrite sheets in portable devices fail to effectively contain magnetic fields, leading to increased magnetic field leakage, necessitating a solution for maintaining shielding performance while maintaining thinness.
Innovation Solution
A composite ferrite sheet is manufactured by attaching insulating composite sheets with flake-shaped metal powder particles to both surfaces of a ferrite sheet, using a resin-based slurry applied and rolled onto the ferrite sheet, which are then integrated and thermally compressed, allowing for efficient magnetic field containment without the need for an adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If ferrite sheets are thinned to meet portable device requirements, then device thickness is reduced, but magnetic field containment capability deteriorates
Solution Approach 1:
The patent applies composite materials by combining ferrite particles with a resin matrix to create a composite ferrite sheet. This composite structure maintains thin thickness while achieving effective magnetic field containment through the distributed ferrite particles within the resin, resolving the contradiction between reduced thickness and maintained shielding capability
2Strength
If composite sheets are attached using adhesive, then bonding strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the bonding function into the composite sheet structure itself by using a resin-based slurry that acts as both the composite material matrix and the bonding agent. This eliminates the need for separate adhesive layers and simplifies the manufacturing process while maintaining strong bonding between the composite sheet and ferrite sheet
3Reliability
If multiple manufacturing steps are used to attach composite sheets, then bonding reliability is improved, but production time increases
Solution Approach 1:
The patent applies preliminary action by pre-mixing the resin slurry with ferrite particles to create a ready-to-use composite material that can be directly applied and bonded in a single step. This pre-prepared composite slurry eliminates the need for multiple sequential steps of applying adhesive, attaching sheets, and curing, thereby reducing production time while maintaining bonding reliability
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 composite ferrite sheet effectively enhances magnetic field containment, improving shielding efficiency and maintaining a relatively thin thickness, thus reducing magnetic field leakage and enhancing the performance of wireless charging apparatuses.
Implementation Method 1
forming composite sheets having insulating properties on both surfaces of the ferrite sheet, respectively... applying the slurry to both surfaces of the ferrite sheet; and rolling the ferrite sheet and the slurry, to press and bond the slurry to both surfaces of the ferrite sheet
Implementation Method 2
integrating the composite sheets with the ferrite sheet by compressing the composite sheets... applying heat to the composite sheets to thermally compress the composite sheets
Implementation Method 3
The composite sheet may be formed of a resin containing metal powder particles... The metal powder particles may include at least any one of a sendust-based metal, a Permalloy-based metal, and an amorphous metal... effectively enhances magnetic field containment
Data Source
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AI summary
A composite ferrite sheet may include a ferrite sheet, and composite sheets attached to both surfaces of the ferrite sheet, respectively, and having insulating properties. The composite sheet may be formed of a resin containing metal powder particles. The composite ferrite sheet may be easily manufactured and have improved shielding performance.