Magnetic Heating Element Composition for Induction Bonding
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Solution Overview
Problem
Existing magnetic heating elements require high external magnetic field intensities to generate heat effectively, leading to inefficient adhesive bonding and potential thermal deformation due to their reliance on superparamagnetism and small particle sizes, which limits their heating capability and bonding speed.
Innovation Solution
A magnetic heating element with a specific composition (M1-x-yMbxFey)1Fe2-zMczO4, where Ma is cobalt and Mb/Mc are specific metals, and a self-propagating combustion method for mass production, allowing for grain and powder sizes that optimize heating performance even at low magnetic field intensities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If small particle size (100 nm or less) is used to maintain superparamagnetism, then superparamagnetic properties are preserved, but heat generation capability deteriorates and extremely high external magnetic field intensity is required
Solution Approach 1:
The patent changes the particle size parameter from 100 nm or less to 100 nm to 30 μm, and modifies the compositional parameters by incorporating specific metal elements (Co, Ni, Cu, Zn, Mn, Mg, Ca, Sr, Ba, Pb) in controlled ratios. This allows the material to generate sufficient heat at low external magnetic field intensities while maintaining magnetic properties through compositional optimization rather than relying solely on small particle size superparamagnetism
Solution Approach 2:
The patent creates a composite magnetic heating element by combining multiple metal elements (Co, Ni, Cu, Zn, Mn, Mg, Ca, Sr, Ba, Pb) with iron oxide in specific ratios. This composite approach allows the material to exhibit enhanced magnetic heating properties and generate sufficient heat at low external magnetic field intensities without requiring extremely small particle sizes
2Reliability
If small particle size (100 nm or less) is used for heat generation, then superparamagnetism is maintained, but bonding speed deteriorates due to insufficient heating value
Solution Approach 1:
The patent changes the particle size parameter to 100 nm to 30 μm and optimizes compositional parameters by incorporating multiple metal elements in controlled ratios, enabling the material to achieve high heating values that drive rapid adhesive curing and high-speed bonding while maintaining stable magnetic properties
3Power
If high external magnetic field intensity is applied to generate heat, then heat generation is sufficient, but thermal deformation of adherends increases
Solution Approach 1:
The patent modifies the material composition by incorporating multiple metal elements (Co, Ni, Cu, Zn, Mn, Mg, Ca, Sr, Ba, Pb) in specific ratios and optimizes particle size to 100 nm to 30 μm, enabling the magnetic heating element to generate sufficient heat at low external magnetic field intensities, thereby minimizing thermal deformation of adherends while maintaining effective bonding
4Reliability
If nanoparticle dispersion in non-magnetic matrix is used to prevent aggregation, then superparamagnetism is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent changes the particle size parameter to 100 nm to 30 μm and optimizes compositional parameters by incorporating multiple metal elements in controlled ratios, which reduces the critical need for ultrafine nanoparticle dispersion and simplifies the manufacturing process while maintaining stable magnetic properties and preventing aggregation
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 magnetic heating element achieves high heating values at low magnetic field intensities, enhancing adhesive performance, enabling high-speed bonding while minimizing thermal deformation and simplifying the production process.
Implementation Method 1
Induction heating refers to a process in which an external magnetic field is generated with an alternating current flowing through an induction coil, and a magnetic heating element self-heats by the generated external magnetic field
Implementation Method 2
In this case, problems occur in that heat cannot be generated by Neel relaxation and/or Brownian relaxation, and in order to generate heat by Hysteresis loss, an external magnetic field intensity is required to be extremely high
Data Source
AI summary
The present disclosure relates to a magnetic heating element, an induction heating-type adhesive including the same, and a method of preparing the magnetic heating element. The magnetic heating element according to an embodiment of the present disclosure has a composition with an atomic ratio represented by the following formula, (Ma1-x-yMbxFey)1Fe2-zMczO4, wherein: Ma is cobalt (Co), Mb is one or more of zinc (Zn), Copper (Cu), Manganese (Mn), and Magnesium (Mg), and Mc is one or more of samarium (Sm), yttrium (Y), cerium (Ce), europium (Eu), neodymium (Nd), and dysprosium (Dy); 0.01≤x<0.6, 0≤y≤0.4, x+y<1, 0≤z≤0.5; and the magnetic heating element has a grain size of 40 nm to 500 nm, and powder of the magnetic heating element has a particle size of 100 nm to 30 μm. Accordingly, the adhesive including the magnetic heating element may improve adhesive performance and provide high-speed bonding.