Nanocrystalline Magnetic Sheet Structure for High-Power Wireless Charging
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Solution Overview
Problem
Existing nanocrystalline magnetic conductive sheets for wireless charging have low saturation magnetic induction intensity, limiting high-power charging capabilities and causing increased heat loss and thickness issues, while current solutions with adhesive layers for insulation compromise magnetic permeability and appearance.
Innovation Solution
A nanocrystalline magnetic conductive sheet with a composition of Fe(100-y-z-α-β)CuyNbzSiαBβ, prepared through a single roll rapid quenching method and a twice annealing process, followed by magnetic fragmentation, which enhances saturation magnetic induction and eliminates the need for adhesive layers within the nanocrystalline gaps, using a thin double-sided adhesive for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the single-layer nanocrystalline strip is increased to enhance saturation current characteristic, then the saturation current characteristic is improved, but the high frequency loss increases and heat generation increases
Solution Approach 1:
The patent divides the single-layer nanocrystalline strip into multiple thin layers (first nanocrystalline magnetic strip and second nanocrystalline magnetic strip) stacked together. This segmentation allows each layer to maintain thin dimensions with low high-frequency loss while the combined structure achieves the required saturation current characteristic and magnetic shielding effectiveness.
Solution Approach 2:
The patent creates a composite magnetic sheet structure by stacking multiple nanocrystalline magnetic strips with different orientations (first strip along first direction, second strip along second direction perpendicular to first direction). This composite structure optimizes both the saturation current characteristic and reduces high-frequency losses through directional arrangement.
2Reliability
If the thickness of the single-layer nanocrystalline strip is increased to enhance saturation current characteristic, then the saturation current characteristic is improved, but the overall thickness of the magnetic sheet increases
Solution Approach 1:
The patent segments the thick single-layer structure into multiple thin layers stacked together. Each thin layer contributes to the overall magnetic performance while maintaining thin individual dimensions, thus achieving high saturation current characteristic without increasing the overall thickness of the magnetic sheet.
Solution Approach 2:
The patent transitions from a single-layer thick structure to a multi-layer stacked structure, utilizing the vertical stacking dimension to achieve the required magnetic performance. The first and second nanocrystalline magnetic strips are arranged in different spatial directions, optimizing performance within constrained thickness.
3Strength
If protective film is added for fragmentation protection, then appearance is protected, but the protective film must be peeled off which causes nanocrystal fall off and performance degradation
Solution Approach 1:
The patent removes the problematic protective film that required peeling off. Instead, it uses a surface protective film that provides appearance protection and nanocrystal retention without requiring removal, thereby preventing nanocrystal fall-off and maintaining magnetic performance throughout the product lifecycle.
Solution Approach 2:
The patent applies a thin surface protective film that provides sufficient protection for appearance and nanocrystal retention without excessive thickness that would interfere with magnetic performance. The protective film is applied only on the surface rather than penetrating into the gaps.
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 increases charging power by over 30% without increasing overall thickness, improves anti-saturation performance, and maintains low magnetic loss, while ensuring a thin and durable magnetic sheet design.
Implementation Method 1
preparing an alloy with a composition of Fe(100-y-z-α-β)CuyNbzSiαBβ into an alloy strip with an initial state of amorphousness by a single roll rapid quenching method
Implementation Method 2
annealing an amorphous alloy strip according to a preset annealing process, to obtain a single-layer nanocrystalline strip
Implementation Method 3
annealing an amorphous alloy strip according to a preset annealing process, to obtain a single-layer nanocrystalline strip
Implementation Method 4
performing a magnetic fragmentation process on the single-layer nanocrystalline strip or a multi-layer nanocrystalline strip
Data Source
AI summary
A nanocrystalline magnetic conductive sheet for wireless charging and a preparation method therefor are provided. The nanocrystalline magnetic conductive sheet includes a composition of Fe(100-x-y-z-α-β-γ)MxCuyM′zSiαBβXγ, saturation magnetic induction is greater than or equal to 1.25T. The preparation method includes preparing an alloy with a preset composition of into an alloy strip with an initial state of amorphousness by a single roll rapid quenching method, annealing an amorphous alloy strip according to a preset annealing process, to obtain a nanocrystalline strip, performing a magnetic fragmentation process on the nanocrystalline strip, to obtain the nanocrystalline magnetic conductive sheet for wireless charging.