Laminated Inductor Sheet With Thermoset Layer for Stable Processing
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Solution Overview
Problem
Conventional sheet-shaped inductors with magnetic layers experience instability in processing, such as deformation and significant variations in magnetic permeability, when subjected to surface treatments like slitting or immersion in chemical solutions.
Innovation Solution
A laminated sheet with a sheet-shaped inductor and a processing stability layer containing a thermosetting resin composition, including a binder and magnetic particles, is developed. The processing stability layer is applied on the inductor's surfaces, comprising a cured product with thermosetting resin as a main component and optional spherical or flat-shaped inorganic particles, enhancing the sheet's stability during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the surface of the inductor is subjected to processing (slitting or immersion in chemical solutions), then the processing capability is improved, but the magnetic permeability varies greatly and the surface may be deformed
Solution Approach 1:
A protective layer comprising a cured product of a thermosetting resin composition is applied to the surface of the inductor. This protective layer acts as an intermediary between the chemical solutions and the magnetic layer, preventing direct contact and thus preventing deformation of the surface and variations in magnetic permeability while still allowing the inductor to undergo necessary processing operations
2Ease of manufacture
If the surface of the inductor is subjected to processing (slitting or immersion in chemical solutions), then the processing capability is improved, but the surface of the inductor may be deformed
Solution Approach 1:
The protective layer serves as a mediator that shields the magnetic layer from mechanical and chemical stresses during processing operations. This layer prevents surface deformation caused by slitting and immersion in chemical solutions while permitting the processing to proceed
3Reliability
If a protective layer is added to improve processing stability, then the processing stability is improved, but the device complexity increases
Solution Approach 1:
The protective layer is formed from a thermosetting resin composition containing specific particles (such as silica or alumina) that provide both mechanical protection and chemical resistance. This composite material approach achieves high processing stability while maintaining a relatively simple single-layer structure that can be applied in one coating step
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 laminated sheet exhibits excellent processing stability, with magnetic permeability changes of 5% or less after exposure to various chemical solutions, ensuring reliable performance and mountability.
Implementation Method 1
the processing stability layer includes a cured product of a thermosetting resin composition; and the thermosetting resin composition includes a thermosetting resin as an essential component
Data Source
AI summary
A laminated sheet includes a sheet-shaped inductor including a plurality of wirings and a magnetic layer embedding the plurality of wirings, and a processing stability layer disposed on at least one surface in a thickness direction of the inductor. The magnetic layer includes a binder and a magnetic particle having a generally flat shape and whose material is a metal. The processing stability layer includes a cured product of a thermosetting resin composition. The thermosetting resin composition includes a thermosetting resin as an essential component. The thermosetting resin composition includes at least one kind of particle, as an optical component, selected from the group consisting of a first particle having a generally spherical shape and a second particle having a generally flat shape and whose material is an inorganic compound.