Magnetic Resin Composition Balancing Sheet Processability and Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resin compositions used in forming resin sheets for inductor boards suffer from decreased mechanical strength when incorporating polymer compounds with a weight-average molecular weight of about 30000, which compromises the performance of the cured product.
Innovation Solution
A resin composition comprising a combination of a resin with a weight-average molecular weight of 600 or more, an epoxy resin, an amine type dispersant, and a magnetic powder, which enhances specific magnetic permeability, lowers the loss factor, and improves mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polymer compound with a weight-average molecular weight of about 30000 is included in the resin composition, then the resin composition can be processed into a resin sheet, but the mechanical strength of the resin composition layer decreases
Solution Approach 1:
The patent changes the molecular weight parameter of the resin from the conventional about 30000 to 600 or more (specifically using resins with molecular weights in the range of 600-100000, preferably 1000-50000). This parameter change resolves the contradiction by achieving both good processability and high mechanical strength in the cured product.
Solution Approach 2:
The patent creates a composite resin composition system combining a resin (with molecular weight ≥600), epoxy resin, amine type dispersant, and magnetic powder. This composite approach allows the resin to provide structural integrity and mechanical strength while the epoxy resin and magnetic powder contribute to curing properties and magnetic performance, respectively.
2Strength
If a resin with appropriate molecular weight is used to improve mechanical strength, then the cured product has better strength, but the specific magnetic permeability and loss factor may deteriorate
Solution Approach 1:
The patent formulates a composite resin composition containing resin (molecular weight ≥600), epoxy resin, amine type dispersant, and magnetic powder. This composite system achieves synergistic effects where the resin provides mechanical strength, the epoxy resin enables curing and crosslinking, the amine type dispersant ensures uniform magnetic powder distribution, and the magnetic powder provides the required magnetic properties including specific magnetic permeability and low loss factor.
Solution Approach 2:
The patent optimizes the molecular weight parameter of the resin to be 600 or more (specifically 1000-50000 in preferred embodiments), which balances mechanical strength and magnetic properties. Additionally, the patent controls the content ratios of each component in the resin composition to achieve optimal performance.
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 composition produces a cured product with high specific magnetic permeability, low loss factor, and excellent mechanical strength, suitable for forming resin sheets, circuit boards, and inductor components.
Implementation Method 1
an amine type dispersant
Implementation Method 2
an epoxy resin, an amine type dispersant
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Provided is a resin composition including: (A) a resin having a weight-average molecular weight of 600 or more; (B) an epoxy resin excluding those falling under the component (A); (C) an amine type dispersant, and (D) a magnetic powder.