Magnetic Paste Composition for Uniform Powder Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to prevent uneven distribution of magnetic powder in magnetic pastes, which affects the formation of magnetic layers in inductor elements, leading to issues with relative magnetic permeability and viscosity, especially during storage and degassing processes like centrifugal degassing.
Innovation Solution
A magnetic paste with a specific particle diameter distribution of magnetic powder, ranging from 0.2 μm to 8.5 μm, combined with a binder resin, such as epoxy resin, and optional additives like curing accelerators and dispersants, ensures uniform distribution and enhanced relative magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic powder is used in magnetic paste for inductor element formation, then magnetic properties are achieved, but magnetic powder sediments and becomes unevenly distributed during storage and centrifugal degassing
Solution Approach 1:
The patent applies parameter changes by carefully controlling the particle diameter distribution of magnetic powder within specific ranges (D10: 0.2-2.0 μm, D50: 2.0-4.3 μm, D90: 4.3-8.5 μm) and adjusting the viscosity of the magnetic paste to prevent sedimentation while maintaining magnetic properties. This resolves the contradiction by optimizing physical parameters to achieve both magnetic functionality and compositional stability.
2Ease of operation
If magnetic powder with larger particle diameter is used, then easier handling is achieved, but magnetic powder sediments more easily causing uneven distribution
Solution Approach 1:
The patent resolves this contradiction by optimizing the particle diameter distribution parameters, setting D90 between 4.3-8.5 μm for adequate handling while limiting D10 to 0.2-2.0 μm to prevent excessive sedimentation. The controlled size distribution ensures particles are neither too large (prone to sedimentation) nor too small (difficult to handle), achieving a balance between operability and stability.
3Reliability
If magnetic paste is subjected to centrifugal degassing, then air bubbles are removed, but magnetic powder becomes unevenly distributed
Solution Approach 1:
The patent resolves this contradiction by adjusting the viscosity parameter of the magnetic paste to an optimal range that provides sufficient resistance to magnetic powder movement during centrifugal degassing. This controlled viscosity allows air bubbles to be removed effectively while preventing magnetic powder from separating unevenly, maintaining both quality and uniformity.
4Reliability
If magnetic powder content is increased to achieve desired relative magnetic permeability, then magnetic performance is improved, but viscosity decreases making it difficult to form magnetic layer
Solution Approach 1:
The patent resolves this contradiction by optimizing multiple parameters simultaneously: controlling particle diameter distribution to reduce aggregation, adjusting viscosity to an optimal range, and optimizing the magnetic powder content within specific limits. This multi-parameter optimization achieves the desired relative magnetic permeability while maintaining sufficient viscosity for proper magnetic layer formation.
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 paste with a predetermined particle diameter distribution allows for easier dispensing and forms a magnetic layer with improved relative magnetic permeability, reducing sedimentation and viscosity issues, enabling effective inductor element formation.
Implementation Method 1
magnetic powder has a higher specific gravity, and therefore, for example, during storage, with the passage of time, the magnetic powder contained in a magnetic paste sediments and is sometimes unevenly distributed
Implementation Method 2
when a magnetic paste is prepared or before the magnetic paste is used, a degassing operation, such as vacuum degassing or centrifugal degassing, is sometimes performed
Data Source
AI summary
Magnetic pastes which include a magnetic powder (A) and a binder resin (B), in which, in the particle diameter distribution of the component (A), the 10% particle diameter (D10) is 0.2 μm or larger and 2.0 μm or smaller, the 50% particle diameter (D50) is 2.0 μm or larger and 4.3 μm or smaller, and the 90% particle diameter (D90) is 4.3 μm or larger and 8.5 μm or smaller, suppress the magnetic powder from being unevenly distributed, and are useful for forming inductor elements and circuit boards.