Conductive Magnetic Composite Sheet for Antenna Delamination
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Solution Overview
Problem
Existing antenna devices in mobile devices face efficiency and performance issues due to limited internal space and weak adhesiveness between circuit boards and magnetic sheets, leading to potential delamination during high-temperature processes like reflow or soldering, especially when used for applications like near field communication, wireless power charging, and magnetic secure transmission.
Innovation Solution
A method of preparing a conductive magnetic composite sheet by stacking a magnetic sheet with a binder resin and a conductive foil, applying heat and pressure to bond them together, which enhances interlayer adhesion and magnetic properties, and forming an antenna pattern by etching the conductive foil, thereby improving the antenna device's performance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetic sheet is bonded to a circuit board to improve magnetic properties and prevent eddy current, then magnetic performance is improved, but internal space efficiency is reduced
Solution Approach 1:
The patent combines the magnetic sheet and conductive foil into a single integrated conductive magnetic composite sheet, merging two separate functional layers into one component that provides both magnetic shielding and eddy current prevention without requiring additional space for separate layers
Solution Approach 2:
The patent creates a composite material structure by laminating conductive foil onto a magnetic sheet, forming a conductive magnetic composite sheet that integrates the properties of both materials into a single functional component with dual functionality
2Reliability
If a magnetic sheet is attached to a circuit board to improve magnetic flux focusing, then antenna performance is improved, but interlayer adhesion is weak causing delamination
Solution Approach 1:
The patent merges the magnetic sheet and conductive foil into an integrated composite sheet with strong internal bonding, eliminating the weak adhesion interface between separate layers that causes delamination in conventional structures
Solution Approach 2:
The conductive foil is pre-laminated onto the magnetic sheet during manufacturing to create strong interlayer adhesion before the composite sheet is installed in the antenna device, preventing delamination during subsequent high-temperature reflow or soldering processes
3Adaptability or versatility
If a conductive foil is laminated on a magnetic sheet to form antenna pattern, then antenna functionality is achieved, but strong interlayer adhesion is required to prevent delamination during heat treatment
Solution Approach 1:
The patent creates a composite material structure where conductive foil is permanently bonded to magnetic sheet through lamination, forming an integrated conductive magnetic composite sheet that maintains strong adhesion during high-temperature heat treatment while enabling antenna patterning functionality
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 conductive magnetic composite sheet achieves excellent interlayer adhesion and magnetic properties, preventing delamination under severe conditions, reducing the need for separate adhesive layers, and enhancing process efficiency while maintaining magnetic performance for NFC, WPC, and MST applications.
Implementation Method 1
the binder resin may be a thermosetting resin, and the binder resin may bond the magnetic sheet to the first conductive foil while being cured in the step of applying heat and pressure to the stack
Implementation Method 2
applying heat and pressure to the obtained stack to bond the magnetic sheet and the first conductive foil together
Implementation Method 3
applying heat and pressure to the obtained stack to bond the magnetic sheet and the first conductive foil together
Implementation Method 4
This uses a principle that a magnetic body, such as the ferrite sheet, focuses the magnetic flux of the antenna so that the penetration of a magnetic field into a metal surface and the generation of the eddy current may be prevented
Implementation Method 5
stacking the magnetic sheet and a first conductive foil; applying heat and pressure to the obtained stack to bond the magnetic sheet and the first conductive foil together
Data Source
AI summary
According to a method of preparing a conductive magnetic composite sheet, the method comprising preparing a magnetic sheet comprising a magnetic powder and a binder resin; stacking the magnetic sheet and a first conductive foil; and applying heat and pressure to the obtained stack to bond the magnetic sheet and the first conductive foil, a conductive magnetic composite sheet having excellent interlayer adhesion between the magnetic sheet and the conductive foil can be prepared while having an excellent magnetic property at NFC, WPC, and MST frequencies.