Multilayer Magnetic Sheet Joining for Discontinuous Ribbon Sections
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Solution Overview
Problem
The manufacturing of multilayer magnetic sheets faces challenges due to reduced strength of alloy ribbons after thermal treatment, leading to gaps and discontinuities, which impair their characteristics as magnetic shields or yoke members, making it difficult to use them effectively in contactless charging applications.
Innovation Solution
A method involving a magnetic sheet configuration with adjacent magnetic ribbons bonded by an adhesive layer and a resin sheet, where the ribbons are cut to have end portions with a specific distance relationship, allowing for the use of discontinuous portions and enabling connection of shorter laminates to achieve the desired length, thereby maintaining required characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If alloy ribbons are thermally treated to crystallize and achieve desired characteristics, then magnetic properties are improved, but strength is reduced causing gaps and discontinuities
Solution Approach 1:
The alloy ribbons are divided into multiple pieces along the longitudinal direction, creating a segmented structure. This segmentation allows each segment to be independently handled and bonded, preventing gaps and discontinuities while maintaining the desired magnetic characteristics achieved through thermal treatment.
Solution Approach 2:
The alloy ribbons are thermally treated before bonding to achieve the desired magnetic characteristics in advance. By performing the thermal treatment beforehand, the magnetic properties are optimized while the subsequent bonding process ensures structural integrity despite the reduced strength from thermal treatment.
2Ease of manufacture
If alloy ribbons are cut to manageable lengths for bonding, then ease of manufacture is improved, but gaps and discontinuities occur impairing magnetic characteristics
Solution Approach 1:
A bonding layer is introduced as an intermediary between the alloy ribbon pieces. This bonding layer facilitates the connection of cut segments, ensuring continuous magnetic characteristics while allowing the ribbons to be cut to manageable lengths for the bonding process.
3Reliability
If multiple alloy ribbons are layered to form multilayer magnetic sheet, then magnetic shielding effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The multilayer magnetic sheet is constructed by bonding multiple alloy ribbon pieces in layers, with each layer segmented into manageable sections. This segmented approach simplifies the manufacturing process while maintaining the magnetic shielding effectiveness provided by the multilayer structure.
Solution Approach 2:
The alloy ribbons are thermally treated and segmented before assembly into the multilayer structure. By preparing the ribbons in advance with the desired magnetic characteristics and appropriate segmentations, the subsequent layering and bonding processes are simplified.
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
This approach facilitates the manufacturing of multilayer magnetic sheets with improved characteristics by ensuring adjacent ribbons maintain required properties, even if cut or discontinuous, and allows for seamless integration in contactless charging devices.
Implementation Method 1
an adhesive layer (also referred to as 'bonding layer') is disposed between adjacent alloy ribbons. The adhesive layer functions to bond the adjacent alloy ribbons to each other
Implementation Method 2
by manufacturing a non-crystalline alloy ribbon and performing the thermal treatment on the alloy ribbon to crystallize the alloy ribbon, the alloy ribbon has desired characteristics
Data Source
AI summary
A magnetic sheet includes a first magnetic sheet, a second magnetic sheet, and a fixing tape. Each of the first magnetic sheet and the second magnetic sheet includes an adhesive layer including a support formed in a band shape and an adhesive, a magnetic ribbon that is formed in a band shape using a magnetic material and is bonded to the adhesive layer, and a resin sheet that is formed in a band shape using a resin material and is disposed on the adhesive layer. The fixing tape fixes an end portion in a longitudinal direction of the magnetic ribbon in the first magnetic sheet and an end portion in a longitudinal direction of the magnetic ribbon in the second magnetic sheet in a state where the end portions are adjacent to each other with a distance equal to or less than a predetermined value.