Plastic Magnetic Material with Organic Silicon Adhesive Layer
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Solution Overview
Problem
Conventional rubber and plastic magnets face issues with resource waste, adhesive residue, and high costs due to the dependence on magnetic powder content, which affects attraction force and durability, and the use of UV curing methods leads to environmental and health concerns.
Innovation Solution
A high-performance plastic magnetic material comprising a low surface energy layer, a magnetic layer, and a printable layer, where the magnetic layer is made with 50% to 90% magnetic powder and a thermoplastic matrix, and an organic silicon pressure-sensitive adhesive layer is used, eliminating the need for UV curing and adhesive residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the content of magnetic powder is increased to improve attraction force, then the attraction force increases, but powder falling and wipe blackening occur more easily
Solution Approach 1:
The patent introduces a binder as an intermediary substance that bonds magnetic powder particles together. The binder forms a matrix that holds the magnetic powder in place, preventing powder falling and wipe blackening while maintaining the magnetic properties. This mediator allows the system to achieve both high attraction force and high reliability without directly increasing magnetic powder content alone.
Solution Approach 2:
The patent creates a composite material system consisting of magnetic powder, binder, and other additives. This composite approach allows optimization of multiple properties simultaneously - the magnetic powder provides attraction force, the binder prevents powder falling, and the combination enables the material to maintain both high magnetic performance and structural integrity.
2Reliability
If matte UV curing surface treatment is applied to prevent powder falling and wipe blackening, then these problems are alleviated, but the surface becomes hard with low friction coefficient, requiring increased thickness or performance improvement of magnetic materials
Solution Approach 1:
The patent extracts and eliminates the UV curing step from the manufacturing process. Instead of applying UV treatment to the surface, the invention uses a binder-based approach that prevents powder falling and wipe blackening during the material formulation stage itself, removing the need for subsequent UV curing and its associated problems.
Solution Approach 2:
The patent replaces expensive UV curing treatment with a simpler, more economical binder-based solution. The binder is incorporated directly into the material composition, providing a cost-effective alternative to UV curing that achieves the same protective function without the need for additional processing steps or equipment.
3Strength
If UV curing is applied to improve surface properties, then hardness and friction coefficient are improved, but UV oil is costly and odorous, and UV monomer and solvent are corrosive causing skin allergy
Solution Approach 1:
The patent converts the harmful effects of UV curing into beneficial properties through the binder system. The binder provides the necessary surface properties and protection without requiring UV radiation, thereby eliminating the harmful effects (cost, odor, corrosiveness) while maintaining or improving the beneficial properties (hardness, friction resistance).
Solution Approach 2:
The patent replaces the chemical/physical process of UV curing with a mechanical bonding approach using binders. Instead of relying on UV light to crosslink and harden the surface, the invention uses binder materials that provide structural integrity and surface properties through their inherent mechanical and chemical bonding characteristics.
4Force
If high content of magnetic powder is used to increase attraction force, then the attraction force increases, but the material becomes brittle and easily breaks off when thickness is increased
Solution Approach 1:
The patent changes the compositional parameters of the material by introducing binders and adjusting the ratio of magnetic powder to binder. This parameter change allows the material to maintain high magnetic powder content for strong attraction force while the binder provides flexibility and toughness to prevent brittleness and breakage.
Solution Approach 2:
The patent creates a composite material structure where magnetic powder is embedded in a binder matrix. This composite approach allows the magnetic powder to provide attraction force while the binder provides structural continuity and toughness, preventing the material from becoming brittle even at high magnetic powder contents.
5Reliability
If general pressure-sensitive adhesive is combined with magnetic material to improve attraction force and reliability, then these properties are improved, but adhesive residue occurs due to short molecular chain, low molecular weight and low cohesion of the resin
Solution Approach 1:
The patent merges the adhesive function with the magnetic material itself by incorporating binder materials that serve both as structural matrix and as the bonding agent. This integration eliminates the need for separate adhesive layers, thereby preventing adhesive residue while maintaining strong attraction force and reliability.
Solution Approach 2:
The binder in the patent performs multiple functions: it holds magnetic powder particles together, provides structural integrity to the material, and serves as the bonding interface with the substrate. This multi-functionality eliminates the need for separate adhesive components, preventing adhesive residue while achieving the desired reliability and attraction force.
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 provides a reliable, environmentally friendly magnetic material with improved material utilization, reduced costs, and enhanced durability without adhesive residue or surface damage, ensuring consistent attraction force and safety.
Implementation Method 1
the magnetic attraction force is dependent on the content of the magnetic powder, the higher the content of the magnetic powder, the greater the attraction force
Implementation Method 2
the problem of wipe blackening or powder falling can be alleviated or solved by matte UV curing surface treatment, however, UV treatment results in high hardness, small friction coefficient
Data Source
AI summary
The invention discloses a high performance plastic magnetic material, comprising a low surface energy layer, a magnetic layer and a printable layer, wherein the magnetic layer and the printable layer are arranged successively on a first side of the low surface energy layer; the low surface energy layer is an organic silicon pressure sensitive adhesive layer. The invention further discloses a preparation method, comprising the following steps: pretreating a magnetic powder with a coupling agent; mixing the pretreated magnetic powder with matrix components and auxiliaries to gain a mixture; extrusion compositing the gained mixture with a printable layer to gain composite paper having the printable layer and a magnetic layer; and applying a low surface energy layer on a side of the magnetic layer, opposite the printable layer. As no UV layer and no adhesive residue, the material of the invention is environmentally friendly and highly reliable.