Ferrite Sheet Gas Discharge Passages Sintering
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Solution Overview
Problem
Conventional ferrite sheet manufacturing methods result in wrinkles or waviness due to binder combustion gas discharge issues during sintering, leading to quality degradation and damage during separation, which affects the productivity and reliability of electromagnetic wave shielding materials.
Innovation Solution
A method involving the use of a transfer base material with repeatedly uneven portions to form gas discharge passages between stacked molded ferrite sheets, allowing for efficient binder gas discharge and minimizing damage during sintering, utilizing a flat plate or roller with specific uneven surface features to enhance sheet separation and sintering processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ferrite sheets are stacked and sintered to improve productivity, then manufacturing efficiency increases, but binder combustion gas cannot be discharged properly causing wrinkles and waviness
Solution Approach 1:
The patent introduces a porous structure by forming through-holes penetrating the ferrite sheets in the stacking direction. These holes create gas discharge passages that allow binder combustion gas to escape during sintering, preventing wrinkles and waviness while maintaining stacked sintering for high productivity
Solution Approach 2:
The patent segments the internal structure of ferrite sheets by creating arrays of through-holes. This segmentation divides the solid ferrite sheet into regions separated by gas passages, enabling efficient gas discharge while maintaining the overall structural integrity and productivity benefits of stacked sintering
2Device complexity
If ferrite sheets are manually separated after sintering to maintain simplicity, then process complexity remains low, but sheet damage occurs frequently
Solution Approach 1:
The porous structure with through-holes reduces adhesion between stacked ferrite sheets by creating separation passages, allowing sheets to be easily separated after sintering without damage while maintaining process simplicity
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 simplifies the manufacturing process, reduces defects like wrinkles and waviness, improves the durability and reliability of ferrite sheets, and enhances the productivity and cost-effectiveness of electromagnetic wave shielding materials.
Implementation Method 1
pressing each of the molded ferrite sheets and the transfer base material to transfer a reverse image of the uneven portions onto a surface of each of the molded ferrite sheets
Implementation Method 2
sintering the ferrite stack
Implementation Method 3
a binder combustion gas, which is generated during a sintering process of molded ferrite sheets
Data Source
AI summary
A ferrite sheet manufacturing method according to the present invention includes (1) stacking a plurality of molded ferrite sheets to prepare a ferrite stack having gas discharge passages between adjacent molded ferrite sheets, and (2) sintering the ferrite stack. According to the present invention, productivity can be increased, and manufacturing costs can be reduced. In addition, a gas generated during combustion of a binder can be discharged using a gas discharge passage between repeatedly uneven portions disposed in one direction, thereby preventing wrinkles or waviness generated in a peripheral portion of a ferrite sheet. Furthermore, since it is possible to improve durability and reliability of an electromagnetic wave shielding material manufactured using the ferrite sheet, the ferrite sheet can be applied to various electronic products.