Magnetic Core Composition With Staged Solvent Evaporation
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Solution Overview
Problem
Conventional integrated inductor manufacturing processes are complex, prone to coil damage during pressure casting, and lack high-temperature resistance, making it difficult to achieve both compactness and high relative permeability, especially at temperatures ranging from 100 to 180°C.
Innovation Solution
A magnetic composite material composition comprising a magnetically soft alloy, thermosetting resin, curing agent, and an organic solvent with a specific volatile solvent blend, allowing for staged curing and controlled volatilization to prevent porosity and enhance compactness and permeability, while avoiding the need for pressure casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pressure casting is used to manufacture integrated inductors, then the inductor body can be formed, but the coil may be damaged or deformed due to excessive pressure
Solution Approach 1:
The patent extracts the coil from the molding process by using a pre-formed coil that is placed into the mold cavity before injecting the magnetic composite material. This separates the coil formation step from the body formation step, allowing the coil to be manufactured independently with higher precision and then integrated into the final product without exposure to high molding pressures.
Solution Approach 2:
The coil is pre-formed and prepared in advance before being placed in the mold cavity. This preliminary action allows the coil to be manufactured with optimal conditions separate from the molding process, ensuring its integrity is not compromised during subsequent high-pressure injection of the magnetic material.
2Ease of manufacture
If conventional pressure casting process is used, then inductor body can be molded, but the production process becomes complex and costly
Solution Approach 1:
The patent merges the coil, magnetic composite material, and encapsulating resin into a single integrated molding process. The pre-formed coil is placed in the mold, magnetic composite material is injected to form the inductor body, and the same mold cavity is used to inject encapsulating resin, all in one continuous operation. This integration simplifies the manufacturing process by eliminating separate assembly steps for coil winding, magnetic material application, and resin encapsulation.
3Ease of manufacture
If single-component magnetic material is used, then the material can be processed, but it cannot work in high-temperature environment (100 to 180°C)
Solution Approach 1:
The patent uses a magnetic composite material consisting of magnetic powder particles dispersed in a cured resin matrix. The resin component provides high-temperature stability and structural integrity, while the magnetic powder provides the necessary magnetic properties. This composite structure enables the material to maintain its performance in high-temperature environments (100 to 180°C) that would be impossible for simple magnetic powders or plastics alone.
4Shape
If complex three-dimensional magnetic structures are molded, then product functionality is improved, but the molding pressure requirement increases causing coil damage
Solution Approach 1:
The patent extracts the coil from the high-pressure molding process by pre-forming it separately and placing it in the mold cavity. This allows the magnetic composite material to be injected at high pressure to create complex three-dimensional structures without the coil being present to suffer damage from the pressure.
Solution Approach 2:
The patent changes the physical state and properties of the magnetic material by using a composite formulation with specific resin and magnetic powder ratios. This composition allows the material to be injected at high pressure while maintaining flowability, then cure to form the desired complex three-dimensional structure with adequate mechanical strength to support intricate geometries.
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 solution enables the production of magnetic cores with high-temperature resistance up to 180°C, compactness, and relative permeability ranging from 10 to 30, preventing coil damage and improving inductance performance.
Implementation Method 1
the organic solvent contains at least two types of volatile solvents, and a difference between boiling points of the volatile solvents ranges from 100 to 170° C.
Implementation Method 2
a magnetic composite material composition comprising a magnetically soft alloy, thermosetting resin, curing agent
Data Source
AI summary
The present disclosure provides a magnetic composite material composition, a magnetic core for an inductor and a manufacturing method therefor. It includes a magnetically soft alloy, a thermosetting resin, a curing agent, and an organic solvent. The organic solvent contains at least two types of volatile solvents, and a difference between boiling points of the volatile solvents ranges from 100 to 170° C. The magnetically soft alloy and the thermosetting resin may be cured and formed under the action of the curing agent. The magnetic composite material of the above composition has good high-temperature resistance. Different types of the volatile solvents may be successively volatilized rather than rapidly volatilized at one time as the curing reaction undergoes. Therefore, a large amount of pores can be prevented from being produced on the surface and internal of the magnetic composite material composition, thereby enhancing the compactness and relative permeability.