Ferrite Sheet Manufacturing via Block Segmentation and Pre-Sintering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing ferrite sheets face challenges in producing complex shapes and large-area sheets without distortion or deformation, due to the brittleness of ferrite and the limitations of the sintering process, which can lead to breakage or warping.
Innovation Solution
A method involving the preparation of a ferrite block body with a cylindrical or polygonal column shape, which is sintered and then cut into plate-shaped sheets with predetermined thickness, allowing for the formation of complex shapes like through-holes before sintering, and using cutting techniques like wire cutting, sawing, or laser cutting to maintain shape integrity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ferrite sheets are manufactured by mixing ferrite powder with binder and sintering, then ferrite sheets can be produced with magnetic characteristics, but the sheets may be distorted or deformed in the sintering process when having large area
Solution Approach 1:
The large-area ferrite sheet is divided into multiple small-sized ferrite blocks, each sintered separately to avoid distortion. These blocks are then assembled together using adhesive to form the complete large-area sheet, thereby maintaining shape precision while achieving the required large dimensions.
Solution Approach 2:
Complex shapes such as arrangement holes and coupling holes are formed in the ferrite blocks before the sintering process. This preliminary shaping avoids the need for post-sintering processing, which would be difficult due to the brittleness of sintered ferrite and the risk of breakage.
2Adaptability or versatility
If ferrite sheets are processed into complex shapes after sintering, then functional features can be added, but the ferrite sheet may be broken or damaged by external force during the work process
Solution Approach 1:
Complex shapes including arrangement holes and coupling holes are formed in the ferrite blocks before sintering. This preliminary action eliminates the need for post-sintering mechanical processing, which would subject the brittle sintered ferrite to high risk of breakage from external forces.
3Area of stationary object
If small-sized ferrite blocks are attached together to manufacture large-area ferrite sheets, then large area sheets can be produced, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The large-area ferrite sheet is segmented into multiple small ferrite blocks that are sintered separately and then assembled. This segmentation allows parallel processing of multiple blocks, improving manufacturing efficiency while achieving large final dimensions.
Solution Approach 2:
Complex shapes are preliminarily formed in the blocks before sintering, eliminating subsequent processing steps. This preliminary action streamlines the overall manufacturing process and improves productivity by reducing the number of operations required after sintering.
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 enables the simple and distortion-free manufacturing of ferrite sheets with complex shapes and large areas, improving productivity and reducing manufacturing costs while maintaining the magnetic characteristics of the ferrite material.
Implementation Method 1
The preparing of the ferrite block body may include shaping a ferrite powder or ferrite slurry into the ferrite block body having a cylindrical or polygonal column shape and sintering the ferrite block body.
Implementation Method 2
The cutting of the ferrite block body may be performed by any one of wire cutting, sawing, waterjet cutting, and laser cutting.
Implementation Method 3
The cutting of the ferrite block body may be performed by any one of wire cutting, sawing, waterjet cutting, and laser cutting.
Data Source
AI summary
A method for manufacturing a ferrite sheet is provided. A method for manufacturing a ferrite sheet comprises the steps of: preparing a ferrite block body having a shape of a cylindrical or polygonal column; and cutting the ferrite block body to be separated into plate-shaped sheets having a predetermined thickness.