Magnetic Film with Oriented Permeable Particles for EMI Shielding
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Solution Overview
Problem
Conventional magnetic films with randomly oriented particles lack efficient electromagnetic absorption and shielding capabilities, limiting their effectiveness in reducing electromagnetic interference (EMI) and thermal conductivity.
Innovation Solution
The development of magnetic films with magnetically permeable particles that are oriented and aligned using magnetic fields to form continuous layers, enhancing magnetic permeability, electromagnetic absorption, and thermal conductivity by creating structured layers with specific particle compositions and densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If particles are randomly oriented in conventional magnetic films, then the film structure is simple and easy to manufacture, but electromagnetic absorption and shielding capabilities are insufficient
Solution Approach 1:
The patent applies magnetic fields during the film formation process to preliminarily orient and align particles into continuous layers before the resin cures. This preliminary action of particle arrangement under magnetic field enables the film to achieve superior electromagnetic absorption and shielding capabilities while maintaining a manufacturable process through roll-to-roll coating techniques.
Solution Approach 2:
The patent uses composite materials consisting of magnetically permeable particles dispersed in a resin matrix. The particles are specifically arranged to form continuous layers with high aspect ratios, creating a composite structure that combines the benefits of particle-based magnetic properties with the continuity of layered structures for enhanced electromagnetic interference shielding.
2Temperature
If particles are randomly distributed, then manufacturing process is simple, but thermal conductivity is limited
Solution Approach 1:
The magnetic field is applied during the coating process to preliminarily orient particles into continuous layers before the resin sets. This preliminary orientation action creates thermally conductive pathways through the film while maintaining compatibility with existing roll-to-roll manufacturing processes, achieving improved thermal conductivity without major process changes.
3Reliability
If particles form continuous layers with high aspect ratio, then magnetic permeability and electromagnetic shielding are enhanced, but particle packing density increases complexity
Solution Approach 1:
The patent uses magnetic fields to preliminarily orient and align particles into continuous layers with high aspect ratios during the film formation process. This preliminary action creates the desired complex particle architecture without requiring complex manufacturing equipment, as the magnetic field self-organizes the particles into the required structures.
Solution Approach 2:
The patent changes the magnetic field parameters (strength, direction, duration) to control particle orientation and layer formation. By adjusting these magnetic field parameters, the patent achieves optimal particle arrangement for high magnetic permeability and electromagnetic shielding while maintaining manufacturing feasibility.
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 aligned particle structure significantly improves electromagnetic absorption and shielding effectiveness over a wide frequency range while increasing thermal conductivity, making the films suitable for electronic device protection and thermal management.
Implementation Method 1
The particles can be oriented and/or aligned and/or positioned by the methods described herein
Implementation Method 2
a magnetic film including a plurality of magnetically permeable particles dispersed between opposing first and second major surfaces of the magnetic film
Implementation Method 3
for at least one frequency less than about 1 GHz, μ′1/μ′2≥5
Implementation Method 4
The first and second particles have different compositions. For at least one cross-section of the magnetic film and for each of the first and second particles, the particle has alternating higher and lower densities
Data Source
AI summary
A magnetic film includes a plurality of magnetically permeable particles dispersed between opposing first and second major surfaces of the magnetic film. The first and second major surfaces are spaced apart a distance D. The particles are agglomerated so as to form a plurality of substantially continuous layers of particles generally extending along orthogonal first and second directions and arranged along a third direction. Each substantially continuous layer of particles has a length L along the first direction from a first to an opposing second edge of the magnetic film and a width W along the second direction extending from the first to the second major surface. L/D≥100.