Mn-Zn Ferrite Powder Surface Steps for Resin Adhesion
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Solution Overview
Problem
The production of composite products using spherical or polyhedral ferrite powder and resin results in the detachment of ferrite particles, leading to a decrease in surface smoothness due to poor adhesion between the particles and the resin.
Innovation Solution
A Mn—Zn-based ferrite powder with a spinel phase and stepped features on the surface of the ferrite particles is developed, enhancing adhesion to the resin without impairing formability and filling ability, and preventing magnetic loss in the low frequency band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spherical or polyhedral ferrite powder is used to improve flowability and filling ratio, then formability and electromagnetic shielding properties are improved, but adhesion to resin deteriorates causing particle detachment
Solution Approach 1:
The invention applies local quality by creating stepped features only on the surface of spherical ferrite particles, rather than changing the overall particle shape. This localized modification provides adhesion benefits at the particle-resin interface while preserving the spherical shape that ensures good flowability and filling properties during composite material formation.
Solution Approach 2:
The stepped features are pre-formed on the ferrite particle surfaces before the particles are incorporated into the resin composite. This preliminary surface modification ensures that when the particles are mixed with resin, the stepped structures are already in place to provide mechanical interlocking and improve adhesion, preventing particle detachment during subsequent processing.
2Productivity
If spherical ferrite particles are used to improve flowability, then filling ability is improved, but surface smoothness deteriorates due to particle detachment
Solution Approach 1:
The stepped features are introduced locally on the particle surface without altering the overall spherical shape and size distribution. This allows the particles to maintain excellent flowability and filling ability during composite formation, while the localized surface features prevent detachment and preserve surface smoothness in the final product.
3Reliability
If ferrite particles with high saturation magnetization are used to improve electromagnetic shielding properties, then magnetic performance is improved, but magnetic loss in low frequency band increases
Solution Approach 1:
The invention optimizes the composition parameters of the ferrite particles, specifically controlling the Mn and Zn content within precise ranges (Mn: 3-25 wt%, Zn: 1-20 wt%). This parameter optimization achieves a balance between saturation magnetization and magnetic loss, allowing high electromagnetic shielding performance while minimizing energy loss in the low frequency band (10 kHz to 100 MHz).
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 ferrite powder effectively prevents ferrite particle detachment and maintains high formability and filling ability, while providing superior magnetic properties and electromagnetic shielding performance.
Implementation Method 1
the ferrite particles have a stepped feature with convex polygonal contours on the surfaces thereof
Implementation Method 2
the ferrite powder has a BET specific surface area of 0.35 m2/g to 10.00 m2/g
Implementation Method 3
at least spherical or polyhedral ferrite particles having a spinel phase as a main phase
Data Source
AI summary
Provided are a ferrite powder that inhibits magnetic loss at frequencies lower than 100 MHZ, and when applied to a composite material or a composite body, is capable of preventing particles from coming off without loss of moldability and filling properties, a ferrite resin composite material, and electromagnetic shielding material, electronic material, or electronic component. This ferrite powder is a Mn—Zn ferrite powder containing at least spherical or polyhedral ferrite particles having a spinel phase as a main phase. The ferrite particles also have, at respective surfaces thereof, a step structure having a convex polygonal contour. Furthermore, the BET specific surface area of the ferrite powder is 0.35-10.00 m2/g, and the contained amount of the zinc oxide (ZnO) phase thereof is 0-0.8 mass %.