Flexible Soft Magnetic Core Using Embedded Ferromagnetic Wires
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Solution Overview
Problem
The fragility of ferrite cores in inductive devices and antennae leads to reduced magnetic permeability and inductance, making them unsuitable for applications requiring flexibility and durability, especially in RFID and NFC systems.
Innovation Solution
A flexible soft magnetic core composed of continuous ferromagnetic wires embedded in a polymeric medium, allowing flexibility in two orthogonal directions and maintaining magnetic properties under deformation, replacing traditional fragile ferrite cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ferrite cores are used in inductive devices and antennas, then magnetic permeability and inductance are maintained, but the cores are fragile and prone to cracking under flexion and torsion
Solution Approach 1:
The patent uses composite materials by embedding ferromagnetic particles or wires within a flexible polymeric matrix. This combination provides both the magnetic properties needed for inductive devices and the mechanical flexibility to withstand deformation without cracking, directly resolving the contradiction between reliability and mechanical strength.
Solution Approach 2:
The patent changes the physical state and composition of the magnetic core from solid ferrite to a composite structure with ferromagnetic elements dispersed in a polymeric medium. This parameter change enables the core to maintain magnetic permeability while gaining flexibility and resistance to mechanical failure under flexion and torsion.
2Reliability
If ferrite cores are protected by casting in resin or hard shell, then mechanical protection is improved, but the cores remain intrinsically fragile and can still crack
Solution Approach 1:
The patent merges the magnetic core material with the protective polymeric matrix into a single integrated composite structure. The ferromagnetic particles or wires are embedded within the flexible polymer, eliminating the need for separate protective shells or casting layers, thus reducing device complexity while maintaining reliability.
Solution Approach 2:
The patent uses a flexible polymeric matrix as the protective medium that surrounds and protects the ferromagnetic elements. This flexible polymer provides mechanical protection while allowing the core to bend and deform without cracking, replacing rigid protective shells with a flexible alternative.
3Power
If ferrite cores are used with high L/D ratio for increased inductance, then inductance is improved, but the cores become more susceptible to cracking and mechanical failure
Solution Approach 1:
The patent employs composite materials with ferromagnetic particles or wires in a flexible polymeric matrix, enabling the creation of high L/D ratio cores that maintain both high inductance and mechanical durability. The flexible matrix prevents cracking even when the core is made thin and elongated for increased inductance.
4Adaptability or versatility
If metallic lamination stacks are used to replace ferrite, then flexibility is improved, but the low ohmic resistivity requires additional isolating layers increasing complexity
Solution Approach 1:
The patent uses a composite structure where ferromagnetic particles or wires are embedded in an intrinsically insulating polymeric matrix. This eliminates the need for additional isolating layers between metallic laminations, as the polymer itself provides both the flexible structure and the electrical insulation, reducing device complexity.
Solution Approach 2:
The polymeric matrix serves multiple functions simultaneously: it provides the flexible structure, acts as the binding medium for ferromagnetic elements, and provides electrical insulation between conductive ferromagnetic components. This multi-functionality eliminates the need for separate isolating layers, reducing complexity.
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 flexible core enhances durability and maintains magnetic performance, reducing the number of antennas needed and allowing for thinner, more efficient designs with higher flux density, thus improving the operational range and reliability of devices like RFID and NFC systems.
Implementation Method 1
said parallel magnetic paths being electrically isolated from each other by said polymeric medium
Implementation Method 2
comprising a ferromagnetic material arranged to form parallel magnetic continuous paths within the core
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The flexible soft magnetic core (1) includes parallel continuous ferromagnetic wires (4) embedded in a core body (2) made of the polymeric medium (3). The continuous ferromagnetic wires (4) extend from one end to another end of said core body (2), are spaced apart from each other and are electrically isolated from each other by the polymeric medium (3). The method for producing the flexible soft magnetic core (1) comprises embedding continuous ferromagnetic wires (4) into an uncured polymeric medium (3) by means of a continuous extrusion process, curing the polymeric medium (3) with the continuous ferromagnetic wires (4) embedded therein to form a continuous core precursor (10), and cutting said continuous core precursor (10) into discrete magnetic cores (1).