Magnetic Sheet Local Permeability via Material Layer Segmentation
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Solution Overview
Problem
Conventional methods for manufacturing magnetic sheets are limited in adjusting permeability values, particularly in representing different permeability values on a single sheet, which is necessary for RF components and antennas operating at various frequency bands.
Innovation Solution
A process of forming a different material layer on a green sheet, using a cobalt paste or other material powders mixed with an organic solvent, is applied to specific portions of the sheet before stacking and calcining, allowing for localized adjustment of permeability values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used to adjust permeability by varying constituent components or thermal treatment temperature, then permeability can be adjusted, but the process complexity and manufacturing difficulty increase
Solution Approach 1:
The magnetic sheet is divided into multiple regions with different permeability values by forming different material layers on specific portions of green sheets. This segmentation allows each region to have optimized permeability characteristics without requiring complex global manufacturing process adjustments.
Solution Approach 2:
Different material layers with different magnetic properties are formed on specific portions of the green sheets to create local variations in permeability. This enables different regions of the same magnetic sheet to have different permeability values tailored to specific component requirements.
2Adaptability or versatility
If a single permeability value is used throughout the magnetic sheet, then manufacturing is simpler, but multiple RF components or antennas operating at different frequency bands cannot be supported
Solution Approach 1:
Different material layers are formed on specific portions of green sheets to create regional permeability variations. This allows a single magnetic sheet to support multiple RF components or antennas operating at different frequency bands, each benefiting from optimized local permeability characteristics.
Solution Approach 2:
The magnetic sheet is designed to perform multiple functions by incorporating regions with different permeability values. A single magnetic sheet can simultaneously support various RF components or antennas operating at different frequency bands, eliminating the need for multiple separate magnetic sheets.
3Manufacturing precision
If different material layers are formed on green sheets, then localized permeability adjustment is achieved, but the manufacturing process steps increase
Solution Approach 1:
Different material layers are formed on green sheets before stacking and calcination. This preliminary action allows permeability characteristics to be predetermined in different regions, enabling precise localized control without requiring post-processing adjustments.
Solution Approach 2:
The permeability characteristics are adjusted by changing the material composition of different layers formed on green sheets. By varying the constituent components and their proportions in different regions, precise localized permeability control is achieved before the final calcination process.
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 enables the creation of magnetic sheets with varying permeability values on different regions, facilitating the integration of multiple RF components or antennas operating at distinct frequency bands on a single sheet, enhancing their performance and functionality.
Implementation Method 1
A magnetic sheet manufactured by stacking a plurality of green sheets on top of each other and calcining the stacked plurality of green sheets, in which the plurality of green sheets are stacked after a different material layer is formed on a certain portion of both surfaces or one surface of at least one of the plurality of green sheets
Data Source
AI summary
Disclosed are a magnetic sheet, a method of manufacturing the same and an antenna including the magnetic sheet. In the magnetic sheet manufactured by stacking a plurality of green sheets on top of each other and calcining the stacked plurality of green sheets, the plurality of green sheets are stacked after a different material layer is formed on a certain portion of both surfaces or one surface of at least one of the plurality of green sheets.