Magnetic Powder with Insulating Particles for High Resistance
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Solution Overview
Problem
Existing composite magnet technologies face challenges in achieving high electrical resistance and mass productivity, particularly in coating flat magnetic powder particles effectively and maintaining their flat shape during the coating process.
Innovation Solution
A magnetic powder comprising first and second soft magnetic metal particles with inorganic insulating particles, where the insulating particles are attached to the first magnetic particle and used to attach the second magnetic particles, formed through a process involving a mixture of metal powder and inorganic insulator, flattening, and heat treatment to enhance electrical resistance and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat magnetic powder particles are coated with fine particles to improve electrical resistance and high frequency magnetic permeability, then the coating process requires repeated stirring to coat unexposed surfaces, but this results in low mass productivity due to the time-consuming process
Solution Approach 1:
The magnetic powder particles are pre-coated with insulating particles before forming the composite magnet. This preliminary coating action ensures that all surfaces, including those that would later be hidden, are already coated, eliminating the need for repeated stirring after coating and significantly improving mass productivity while maintaining high electrical resistance
2Reliability
If magnetic particles are pressed and stirred repeatedly to attach glass fine particles, then the insulating properties are sufficient, but the flat shape of magnetic particles may be deformed
Solution Approach 1:
The insulating particles are attached to the magnetic powder particles before the pressing step that forms the composite magnet. By performing the coating action beforehand, the flat shape of the magnetic particles is preserved during pressing, as the insulating particles are already in place and do not require subsequent stirring that would cause deformation
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 achieves high electrical resistance and improved mass productivity by effectively attaching inorganic insulating particles to the magnetic particles, maintaining their flat shape and enhancing magnetic permeability, thus addressing the limitations of existing technologies.
Implementation Method 1
The inorganic insulating particles are attached to the first magnetic particle
Implementation Method 2
The glass fine particles are pressed against and attached to the surfaces of the magnetic particles by pressure and friction force
Data Source
AI summary
A magnetic powder comprises a first magnetic particle, one or more inorganic insulating particles and one or more second magnetic particles. The first magnetic particle is made of a soft magnetic metal. The first magnetic particle has a flat shape. The inorganic insulating particles are attached to the first magnetic particle. The inorganic insulating particles partially cover the first magnetic particle. Each of the second magnetic particles is made of a soft magnetic metal. Each of the second magnetic particles has a flat shape. The second magnetic particles are attached to the first magnetic particle via the inorganic insulating particles.