Fe-Ni Epoxy Resin Composition for Easier Polishing
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Solution Overview
Problem
The use of Fe-Ni alloy powder in resin compositions for through holes in circuit substrates results in high hardness and poor polishing workability, making it difficult to produce inductor substrates with high relative magnetic permeability and increased wiring density.
Innovation Solution
A resin composition combining Fe-Ni alloy powder with an epoxy resin containing nitrogen atoms in its molecular skeleton, along with optional components like a low-viscosity thermosetting resin and a curing agent, to enhance polishing workability and maintain high relative magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Fe-Ni alloy powder is used in resin composition to achieve high relative magnetic permeability, then magnetic performance is improved, but hardness increases and polishing workability deteriorates
Solution Approach 1:
The invention changes the chemical composition parameters of the Fe-Ni alloy powder by adding specific amounts of B (0.01-5 mass%), P (0.01-5 mass%), and Si (0.01-5 mass%) elements. These compositional modifications alter the physical properties of the alloy, specifically reducing its hardness while maintaining high relative magnetic permeability, thereby improving polishing workability without sacrificing magnetic performance
Solution Approach 2:
The invention creates a composite resin composition by combining the modified Fe-Ni alloy powder with a specific epoxy resin system (using a curing agent with primary amino groups). This composite structure allows the resin matrix to bind the magnetic powder particles, and the specific chemical composition of the resin system contributes to reducing the overall hardness of the cured product while maintaining the magnetic properties of the Fe-Ni alloy
2Reliability
If Fe-Ni alloy powder with crystal structure is used to maintain high relative magnetic permeability, then magnetic properties are improved, but hardness increases making polishing difficult
Solution Approach 1:
The invention modifies the crystal structure parameters of the Fe-Ni alloy by introducing B, P, and Si elements in specific concentrations. These elements act as alloying additives that disrupt the perfect crystal lattice, reducing crystallinity and thereby lowering hardness. The controlled impurity levels (total of 0.01-15 mass%) are sufficient to affect crystal structure but not enough to compromise the magnetic permeability
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 composition achieves a cured product with improved polishing workability and reduced magnetic loss, enabling the production of circuit and inductor substrates with enhanced properties.
Implementation Method 1
an epoxy resin containing one or more nitrogen atoms in a molecular skeleton thereof
Implementation Method 2
The Fe-Ni alloy powder has a crystal structure thereby having a high relative magnetic permeability
Data Source
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AI summary
A resin composition includes (A) a Fe-Ni alloy powder and (B) an epoxy resin containing one or more nitrogen atoms in a molecular skeleton thereof, in which the component (A) contains one or more elements selected from the group consisting of B, P, and Si.