Continuous Elongate Ferrite Sheet for Gap-Free Magnetic Performance
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Solution Overview
Problem
The existing methods for manufacturing elongate ferrite sheets face challenges such as breakage, limited size, and deterioration of magnetic properties due to overlapping or gaps between ferrite sintered plates.
Innovation Solution
A continuous elongate ferrite sheet is created by forming a ferrite sintered plate that extends continuously along the longitudinal direction of an elongate base material, eliminating the need for overlapping or gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If multiple ferrite sintered plates are arranged to form an elongate ferrite sheet, then the length of the ferrite sheet can be increased, but gaps appear between the plates causing deterioration of appearance and magnetic properties
Solution Approach 1:
The invention divides the elongate ferrite sheet into multiple segments corresponding to individual ferrite sintered plates, each segment being pasted to the base material. This segmentation allows the sheet to be manufactured in manageable sections while maintaining overall elongate structure and functionality.
Solution Approach 2:
The invention introduces an intermediary substance (adhesive or bonding material) between the ferrite sintered plates and the base material to eliminate gaps. This intermediary ensures continuous magnetic properties and improved appearance by creating a seamless bond between adjacent plates.
2Ease of operation
If ferrite sintered plates are pasted to base material to form elongate sheet, then handling ease is improved, but overlapping at joints deteriorates appearance and magnetic properties
Solution Approach 1:
The invention applies local quality control by ensuring that the pasting operation at joint regions matches the quality of non-joint regions. The adhesive application and pressing operations are optimized to eliminate visible overlapping and maintain uniform magnetic properties across the entire elongate sheet.
Solution Approach 2:
The invention uses partial overlapping with excessive adhesive application to ensure complete coverage and elimination of gaps. By applying more adhesive than minimally required and allowing controlled partial overlap, the joint regions achieve appearance quality comparable to non-joint areas while maintaining magnetic continuity.
3Ease of manufacture
If conventional sintering methods are used, then ferrite sintered plates can be produced, but the size is limited to less than 300 mm due to jig and furnace constraints
Solution Approach 1:
The invention segments the elongate ferrite sheet into multiple smaller ferrite sintered plates that can be manufactured using conventional jigs and furnaces. Each plate is produced within the size limitations of existing equipment, then assembled into an elongate configuration to achieve the desired total length.
Solution Approach 2:
The invention transitions from producing a single long ferrite plate in one dimension to producing multiple shorter plates arranged in a sequence along the longitudinal direction. This dimensional reorganization allows circumvention of furnace size constraints while achieving the required overall length through assembly of multiple segments.
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 prevents the deterioration of appearance and magnetic properties, allows for longer sheet lengths without breakage, and facilitates easier handling and application in devices like antenna devices and cables.
Implementation Method 1
a soft magnetic sheet is laminated between the conductive loop coil and the metallic material. The lamination of the soft magnetic sheet forms a route that the magnetic flux can pass through
Implementation Method 2
the communication range is reduced and communication cannot be performed because the magnetic flux is converted as eddy current by the metal
Data Source
AI summary
A ferrite sheet includes a base material and a ferrite sintered plate provided on a surface of the base material. The ferrite sintered plate continuously extends in a longitudinal direction of the base material and has a length of not less than 0.3 m in the longitudinal direction. The elongate ferrite sheet can be formed in a roll shape.