Dust Core Binder Composition for Rust Resistance and Permeability

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Solution Overview

Problem

Existing dust cores for magnetic applications face a contradictory relation between moldability, corrosion resistance, and magnetic permeability, as additives like metal soap powders improve moldability and corrosion resistance but deteriorate magnetic characteristics.

Innovation Solution

Incorporating an epoxy resin with at least two or more mesogenic skeletons between epoxy bonds and an additive containing metallic elements M (Li, Ba, Mg, or Ca) in the dust core, which enhances both rust resistance and permeability simultaneously.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If metal soap powder is added as a lubricant to improve moldability and corrosion resistance, then moldability and corrosion resistance are improved, but magnetic characteristics such as permeability deteriorate

Engineering Contradiction:

ImprovemoldabilityVSAvoidmagnetic characteristics

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention changes the chemical composition parameters of the binder by specifying an epoxy resin with at least two mesogenic skeletons between epoxy bonds. This structural parameter change in the resin allows for better compatibility with metal soap powder additives, enabling improved moldability and corrosion resistance while maintaining magnetic permeability above 25.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite binder system combining epoxy resin with specific mesogenic skeleton structures and metal soap powder additives containing Li, Ba, Mg, or Ca. This composite material approach allows the synergistic effects of the resin structure and additive composition to simultaneously improve moldability, corrosion resistance, and magnetic characteristics.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12512241B2Dust core and electronic device

Publication Date: 2025.12.30 TDK CORP

AI summary

A dust core includes magnetic particles, an epoxy resin, and an additive. The epoxy resin has at least two or more mesogenic skeletons between two epoxy bonds adjacent along a molecular chain. The additive includes one or more metallic elements selected from Li, Ba, Mg, and Ca.