Magnetic Sheet with Convex-Concave Layer for Adhesion-Free Bonding
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Solution Overview
Problem
Conventional magnetic sheets used to suppress electromagnetic interference in electronic devices face issues such as increased thickness due to adhesive layers, which hinder device functionality, and complex, costly production processes, along with surface adhesion problems and impaired appearance from insulating supports.
Innovation Solution
A magnetic sheet comprising a magnetic layer and a convex-concave forming layer with low Bekk smoothness, bonded without adhesives through a hot pressing process, allowing for efficient production and improved surface lubricity, preventing adhesion and enhancing magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive layer is added to bond the magnetic layer and insulating support, then the bonding strength is improved, but the total thickness increases and magnetic permeability decreases
Solution Approach 1:
The adhesive layer is completely removed from the structure. Instead of using an adhesive layer to bond the magnetic layer and insulating support, the patent uses a hot-pressing process that directly bonds these layers without any adhesive, thereby eliminating the thickness contribution from adhesives while maintaining bonding strength
Solution Approach 2:
The bonding process is merged with the lamination process. The magnetic layer, insulating support, and convex-concave forming layer are laminated and bonded simultaneously through hot-pressing, eliminating the need for separate adhesive application and curing steps, thus reducing total thickness while achieving strong bonding
2Strength
If an adhesive layer is added to bond the magnetic layer and insulating support, then the bonding strength is improved, but the production process becomes more complex and costly
Solution Approach 1:
Multiple functions are merged into a single hot-pressing step: lamination of layers, bonding of interfaces, and formation of the convex-concave surface structure. This eliminates separate steps for adhesive application, curing, and surface treatment, simplifying the production process while maintaining bonding strength
Solution Approach 2:
The chemical bonding mechanism of adhesives is replaced with thermal-mechanical bonding through hot-pressing. The heat and pressure directly bond the magnetic layer and insulating support without requiring chemical adhesives, thereby simplifying the production process and reducing costs
3Object-affected harmful factors
If the magnetic sheet thickness is increased to prevent adhesion, then the adhesion prevention is improved, but the device cover opening becomes difficult
Solution Approach 1:
The insulating support provides localized adhesion prevention at the contact interface between the magnetic sheet and battery pack cover, while the convex-concave surface structure provides localized lubricity. This combination prevents adhesion without requiring excessive overall thickness, maintaining ease of cover opening
Solution Approach 2:
The insulating support acts as an intermediary layer between the magnetic layer and the battery pack cover. This intermediate layer prevents direct contact and adhesion between the magnetic layer and cover, while its thin profile (1-10 μm) ensures it does not hinder cover opening operations
4Strength
If a conventional production process with adhesive is used, then the bonding is improved, but the production cost increases
Solution Approach 1:
The adhesive material and its associated processing steps are completely extracted from the production process. The bonding is achieved through direct thermal-mechanical bonding of the layers during hot-pressing, eliminating material costs and processing complexity associated with adhesives
Solution Approach 2:
The magnetic layer and insulating support bond to each other through the hot-pressing process itself, without requiring external adhesives. The layers self-bond under heat and pressure, eliminating the need for separate bonding operations and reducing production costs
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 effectively reduces electromagnetic interference, prevents device cover opening failures, and simplifies production while maintaining high magnetic permeability and surface lubricity, thus addressing the limitations of conventional magnetic sheets.
Implementation Method 1
a magnetic layer comprising a magnetic powder and a resin composition containing the magnetic powder
Implementation Method 2
the convex-concave forming layer has Bekk smoothness of 70 sec/mL or less
Implementation Method 3
bonded without adhesives through a hot pressing process
Data Source
AI summary
A magnetic sheet, which contains: a magnetic layer including a magnetic powder and a resin composition containing the magnetic powder therein; and a convex-concave forming layer, in which the convex-concave forming layer has Bekk smoothness of 70 sec/mL or less. A method for producing a magnetic sheet, which contains: adding a magnetic powder to a resin composition to prepare a magnetic composition, and giving the magnetic composition a shape to form a magnetic layer; and placing and stacking a convex-concave forming layer and a pattern transferring material on a surface of the magnetic layer in this order, and hot pressing the stacked layers so as to bond the convex-concave forming layer with the magnetic layer to form a laminate, as well as to transfer a surface configuration of the pattern transferring material to a surface of the laminate of the convex-concave forming layer and the magnetic layer.