Low-Carbon Ferrite Resin Composition for Printable Magnetic Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resin compositions used to form magnetic layers in inductor substrates face issues with increased viscosity and reduced mechanical strength and elongation properties when the amount of magnetic powder is increased to enhance relative permeability, leading to handling and printing difficulties and potential cracking.
Innovation Solution
A resin composition is formulated with a carbon content of 0.1% or less in the ferrite component, combined with a thermosetting resin, to maintain high relative permeability while reducing viscosity and improving mechanical strength and elongation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the amount of magnetic powder is increased to enhance relative permeability, then the relative permeability of the cured product is improved, but the viscosity of the resin composition increases and the mechanical strength and elongation property deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the carbon content in ferrite to 0.1% or less by mass. This parameter optimization resolves the contradiction by enabling high relative permeability (8 or more at 10 MHz) while maintaining low viscosity and excellent mechanical properties (maximum point strength of 40 MPa or more). The carbon content parameter is the key factor that balances magnetic performance with processability.
2Reliability
If the amount of magnetic powder is increased to enhance relative permeability, then the relative permeability of the cured product is improved, but the mechanical strength and elongation property of the cured product deteriorate
Solution Approach 1:
The patent resolves this contradiction through parameter changes by optimizing the carbon content in ferrite to 0.1% or less by mass. This precise parameter control achieves the dual goal of high relative permeability (8 or more at 10 MHz) and excellent mechanical strength (maximum point strength of 40 MPa or more at 23°C), preventing crack generation while maintaining magnetic performance.
3Reliability
If the amount of magnetic powder is increased to enhance relative permeability, then the relative permeability of the cured product is improved, but the viscosity of the resin composition increases
Solution Approach 1:
The patent applies parameter changes by controlling the carbon content in ferrite to 0.1% or less by mass, which maintains low viscosity of the resin composition. This enables excellent printing properties and handling characteristics while achieving high relative permeability (8 or more at 10 MHz) in the cured product, resolving the contradiction between magnetic performance and printability.
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 resin composition achieves low viscosity, excellent mechanical strength, and enhanced elongation properties, resulting in improved handling and printing capabilities without cracking, thus producing high-performance magnetic sheets, circuit substrates, and inductor substrates.
Implementation Method 1
a resin composition including magnetic powder... a resin composition comprising: (A) a ferrite... a relative permeability (10 MHz) of a cured product obtained by thermally curing the resin composition
Implementation Method 2
a cured product obtained by thermally curing the resin composition at 180°C for 90 minutes... a cured product obtained by thermally curing the resin composition at 190°C for 90 minutes
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
Provided is a resin composition including (A) a ferrite and (B) a thermosetting resin, in which a carbon amount included in the (A) component is 0.1% or less by mass relative to 100% by mass of the (A) component, a relative permeability (10 MHz) of a cured product obtained by thermally curing the resin composition at 180°C for 90 minutes is 8 or more, and a maximum point strength (23°C) of a cured product obtained by thermally curing the resin composition at 190°C for 90 minutes is 40 MPa or more.