Magnetic Core Part Insulating Coating and Insert Molding
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Solution Overview
Problem
Existing methods for producing magnetic core parts face issues such as crack formation, limited shape variability, and reduced magnetic properties, particularly when using amorphous powder materials, which are inferior in moldability and have poor insulation, leading to short circuits and uneven pressure distribution during coil insertion.
Innovation Solution
The method involves coating magnetic powder with an insulating material and using a resin composition for injection molding, incorporating a soft or hard magnetic green compact with a binder having a lower melting point than the injection molding temperature, and positioning it within the coil or around it to enhance magnetic flux density and prevent cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If amorphous powder material is used to improve magnetic properties, then magnetic characteristics are enhanced, but moldability and compactibility deteriorate
Solution Approach 1:
The patent uses composite materials by combining amorphous powder material with a binder material to create a green compact. This composite structure allows the amorphous powder to provide superior magnetic properties while the binder material provides the necessary moldability and compactibility that pure amorphous powder lacks.
2Quantity of substance
If large pressure is applied to the coil during powder compacting to increase density, then filling density is improved, but short circuit occurs due to insufficient insulation coating
Solution Approach 1:
The patent applies preliminary action by coating the magnetic powder particles with an insulating material before compacting. This pre-coating ensures that when large pressure is applied during compacting to achieve high filling density, the insulation coating is already in place to prevent short circuits between particles.
Solution Approach 2:
The patent creates a composite structure where magnetic powder particles are coated with insulating material, forming a core-shell composite. This composite particle structure allows for high filling density while maintaining electrical insulation between adjacent particles during compacting.
3Adaptability or versatility
If electrode terminals are bent after green compact formation to create coil-embedded magnetic part, then integration is improved, but cracks occur in the green compact around terminal leading portions
Solution Approach 1:
The patent applies preliminary action by forming recesses in the green compact at the positions where terminals will be bent, before the actual bending operation. These pre-formed recesses concentrate the stress during bending away from the main body of the green compact, preventing crack formation while still allowing terminal integration.
4Productivity
If resin containing soft magnetic material is used during insert molding to increase productivity, then manufacturing efficiency is improved, but magnetic flux density and direct current bias characteristics deteriorate
Solution Approach 1:
The patent creates a composite structure by insert-molding a green compact (made from amorphous powder with superior magnetic properties) into a resin matrix. This allows the green compact to provide high magnetic flux density and DC bias characteristics, while the resin provides structural support and enables efficient mass production through insert molding.
Solution Approach 2:
The patent applies local quality by using different materials in different regions: the green compact made from amorphous powder is used in regions requiring high magnetic performance, while the resin material is used in regions providing structural support and insulation. This localized material selection optimizes both magnetic properties and manufacturability.
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 increases magnetic flux density, prevents cracks during terminal bending, and simplifies the manufacturing process, allowing for reduced size and improved magnetic bias characteristics, while maintaining cost-effectiveness and suitability for continuous mass production.
Implementation Method 1
coating with an insulating material magnetic powder contained in a resin composition for use in the injection molding
Implementation Method 2
incorporating a soft or hard magnetic green compact with a binder having a lower melting point than the injection molding temperature
Implementation Method 3
injection molding one of a soft magnetic green compact and a hard magnetic green compact into the resin composition
Data Source
AI summary
Magnetic powder contained in a resin composition for use in injection molding is coated with an insulating material, and a soft magnetic green compact or a hard magnetic green compact is insert molded into the resin composition. Increased magnetic flux destiny, reduced size, a simplified shape, and/or increased filling density can be achieved in a core part of an electric instrument.