Magnetic Powder Adhesive Composition for Permeability and Printability
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Solution Overview
Problem
Existing adhesives used in coil components with magnetic powder face challenges in achieving high permeability while maintaining manageable viscosity, leading to difficulties in handling and application.
Innovation Solution
An adhesive comprising a bisphenol F resin, a curing agent, and magnetic powder, with a volume ratio of magnetic powder to adhesive at 35 vol % or lower, and a number average molecular weight of the bisphenol F resin between 312 to 360 g/mol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the proportion of magnetic powder contained in an adhesive is increased to achieve higher permeability, then the permeability is improved, but the viscosity of the adhesive becomes excessively high making it difficult to handle during application
Solution Approach 1:
The patent applies parameter changes by carefully controlling the volume ratio of magnetic powder to adhesive at 35 vol % or lower, and by specifying a narrow molecular weight range (312 to 360 g/mol) for the bisphenol F resin. These parameter optimizations balance permeability enhancement with viscosity control, ensuring the adhesive remains handleable during application while achieving sufficiently high permeability for coil component manufacturing.
2Reliability
If the viscosity of the adhesive is increased to achieve higher permeability, then the permeability is improved, but the adhesive becomes stringy between the jig and top plate during application
Solution Approach 1:
The patent resolves this contradiction by optimizing the molecular weight parameter of the bisphenol F resin to 312 to 360 g/mol and controlling the magnetic powder volume ratio at 35 vol % or lower. These parameter changes prevent excessive viscosity increase that would cause stringiness during application, while still achieving the required permeability for functional performance in coil components.
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 adhesive secures a sufficiently high permeability while being easy to handle and apply, improving the manufacturing efficiency of coil components and maintaining continuous printability.
Implementation Method 1
The adhesive contains magnetic powder
Implementation Method 2
The adhesive is interposed between the top plate and the core and bonds the top plate and the core with each other
Data Source
AI summary
An adhesive includes a bisphenol F resin, a curing agent for the bisphenol F resin, and magnetic powder. The volume ratio of the magnetic powder to the adhesive is 35 vol % or lower. The number average molecular weight of the bisphenol F resin is 312 to 360 g/mol.