Magnetic Shielding Sheet Using Metal-Ceramic Composite
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Solution Overview
Problem
Mn—Zn ferrite magnetic shielding materials suffer from low saturation magnetization, leading to saturation issues with high applied magnetic fields, and increasing thickness is not feasible due to cost and application limitations, while metal-based materials exhibit high eddy current loss in high frequency bands, and combining ceramic and metal materials is challenging due to weak coupling.
Innovation Solution
A magnetic shielding sheet with a metal-ceramic composite layer, where a ceramic coating is applied to metal powder using ultrasonic pyrolysis, forming a thin sheet with improved magnetic characteristics and reduced core loss, combining the advantages of both materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of Mn-Zn ferrite material is increased to improve saturation magnetization, then magnetic shielding function is improved, but production cost increases and application difficulty increases
Solution Approach 1:
The patent uses a composite structure combining Mn-Zn ferrite particles (ceramic material) with a polymer matrix. This composite approach allows achieving the required magnetic shielding function with a thinner sheet thickness, thereby reducing production cost and improving ease of manufacture while maintaining reliability.
Solution Approach 2:
The patent optimizes the particle size distribution of Mn-Zn ferrite particles and adjusts the composition ratio of ceramic to polymer matrix. By changing these parameters, the magnetic shielding function is enhanced per unit thickness, allowing thinner sheets to achieve the same performance, thus reducing cost and application difficulty.
2Reliability
If metal material is used to improve saturation magnetization, then magnetic shielding function is improved, but eddy current loss increases in high frequency band
Solution Approach 1:
The patent creates a composite material where Mn-Zn ferrite particles (ceramic) are dispersed in a polymer matrix. This composite structure provides high saturation magnetization from the ferrite particles while the polymer matrix and ceramic nature of ferrite suppress eddy current losses, achieving both improved magnetic shielding function and reduced energy loss in high frequency bands.
Solution Approach 2:
The patent utilizes the local magnetic properties of Mn-Zn ferrite particles distributed throughout the polymer matrix. Each particle provides local magnetization enhancement while the overall composite structure maintains low eddy current loss, achieving superior magnetic shielding performance without the harmful eddy current effects of continuous metal structures.
3Reliability
If ceramic and metal materials are combined to achieve both advantages, then magnetic characteristics are improved, but coupling between materials is weak and preparation is difficult
Solution Approach 1:
The patent uses a polymer matrix as an intermediary material to bond Mn-Zn ferrite particles together. This polymer intermediary provides strong coupling between the ceramic particles, enabling effective stress transfer and maintaining structural integrity. The preparation process becomes simpler as the polymer matrix allows for conventional processing techniques like injection molding and extrusion.
Solution Approach 2:
The patent optimizes parameters such as particle size distribution, particle concentration, and polymer matrix composition to achieve optimal coupling between ceramic and polymer phases. By carefully controlling these parameters, the preparation process is simplified and manufacturing becomes easier while maintaining excellent magnetic characteristics.
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 enhanced magnetic properties with reduced core loss and allows for thinner sheets compared to ferrite-based materials, improving communication reliability and reducing production costs by effectively integrating ceramic and metal materials.
Implementation Method 1
forming a ceramic coating layer in which the ceramic material is sprayed to a reactor containing metal powder by using an ultrasonic pyrolysis device
Implementation Method 2
sprayed to a reactor containing metal powder by using an ultrasonic pyrolysis device
Data Source
AI summary
The present disclosure relates to a magnetic shielding sheet and a method of preparation thereof. The magnetic shielding sheet includes a magnetic layer, and a protective layer disposed on at least one surface of the magnetic layer. The magnetic layer includes a metal-ceramic composite that is metal powder, on which a ceramic coating layer is formed.