Magnetic Shielding Sheet Flake Treatment for Eddy Current Loss Reduction
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Solution Overview
Problem
Conventional magnetic field shielding sheets for wireless charging face challenges in productivity and cost due to batch heat treatment methods, which lead to brittleness and cracking issues, making roll-to-roll production processes difficult and inefficient.
Innovation Solution
A magnetic field shielding sheet manufactured using a roll-to-roll process with in-line heat treatment, insulating layers, and flake treatment to divide thin film magnetic sheets into fragments, improving flexibility and reducing eddy current losses, while allowing for continuous lamination and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch heat treatment method is used for thin film magnetic sheet, then magnetic permeability is improved, but productivity decreases and manufacturing cost increases due to brittleness and cracking issues
Solution Approach 1:
The patent implements continuous heat treatment through a roller furnace where the thin film magnetic sheet passes through a heating zone continuously. The sheet is fed from a supply reel, heated in-line, and wound onto a take-up reel without interruption, enabling continuous production while achieving the required magnetic permeability without batch processing interruptions
Solution Approach 2:
The patent replaces the conventional batch heat treatment mechanical system with a thermal field system using a roller furnace. The continuous passing sheet undergoes heat treatment through controlled thermal exposure in the furnace zone, eliminating the need for loading/unloading batches and subsequent cooling cycles that cause brittleness and cracking
2Reliability
If batch heat treatment method is used for thin film magnetic sheet, then magnetic permeability is improved, but manufacturing cost increases
Solution Approach 1:
The continuous in-line heat treatment process eliminates idle time between batches, maintains constant thermal processing conditions, and allows for continuous material flow through the production line. This continuity reduces manufacturing costs by eliminating repeated heating/cooling cycles and labor-intensive batch operations while consistently achieving the required magnetic permeability
Solution Approach 2:
The patent combines multiple processes into a single continuous operation: the thin film magnetic sheet is heat-treated in-line within the same production line where it is being manufactured and processed. This integration of heat treatment into the continuous manufacturing flow eliminates separate batch processing steps, reducing overall manufacturing cost while maintaining product quality
3Loss of energy
If flake treatment is applied to reduce eddy current loss, then wireless charging efficiency is improved, but structural integrity may be compromised
Solution Approach 1:
The patent applies flake treatment that divides the continuous thin film magnetic sheet into fine fragmented particles or flakes. This segmentation creates numerous small discontinuities that interrupt eddy current paths, significantly reducing eddy current loss and improving wireless charging efficiency while the flakes remain bound together in a coherent structure
Solution Approach 2:
The flake-treated magnetic sheet creates a composite structure where magnetic flakes are distributed within a binding matrix or coating. This composite architecture maintains structural integrity and flexibility while the fragmented magnetic particles effectively reduce eddy current losses through their discontinuous configuration
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 enhances production efficiency, reduces manufacturing costs, and provides a flexible, crack-resistant magnetic field shielding sheet suitable for wireless charging applications, maintaining high transmission and reception efficiency.
Implementation Method 1
the magnetic permeability of the material increases. In particular, since the wireless charging is essentially a power transmission due to non-contact, it is necessary that the magnetic field shielding sheet on which the secondary coil is mounted is made of a magnetic material having a high magnetic permeability so as to focus the wireless electromagnetic wave generated in the primary coil
Implementation Method 2
the magnetic field shielding sheet reduces eddy current loss by adopting a structure in which the thin film magnetic sheet is separated into a plurality of fine pieces by flake treatment
Implementation Method 3
an adhesive layer formed between the insulating layers of the adjacent thin film magnetic sheets to laminate and bond the thin film magnetic sheets
Data Source
AI summary
Provided are a roll-shaped magnetic field shielding sheet, a method of manufacturing a magnetic field shielding sheet, and an antenna module using the same, which can improve the efficiency of the overall production process by improving a heat treatment process for a thin film magnetic sheet. The magnetic field shielding sheet includes: at least one thin film magnetic sheet; an insulating layer or insulating layers formed on one or either side of the at least one thin film magnetic sheet; and an adhesive layer formed between the insulating layers of the adjacent thin film magnetic sheets to laminate and bond the thin film magnetic sheets, wherein the thin film magnetic sheet is flake-treated to be divided into a plurality of magnetic substance fragments.