Polyethersulfone-Coated Powder Core for High-Temperature Stability
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Solution Overview
Problem
Powder cores used in electric and electronic components undergo significant changes in magnetic properties and mechanical strength when exposed to high-temperature environments, leading to increased core loss and potential thermal denaturation, which affects the stability and reliability of these components.
Innovation Solution
A powder core with an outer coating of polyethersulfone is developed, which maintains magnetic properties and mechanical strength even in high-temperature environments by minimizing stress and thermal denaturation, using a binding component composed of pyrolysis residues and soft magnetic powders like iron-based, nickel-based, crystalline, amorphous, or nanocrystal materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a powder core is used in a high-temperature environment, then the mechanical strength is improved, but the magnetic properties deteriorate due to thermal denaturation
Solution Approach 1:
The invention changes the chemical composition parameters of the outer coating material by specifying that it must contain a polyamideimide-modified epoxy resin with specific functional groups. This chemical parameter change enables the coating to resist thermal denaturation at high temperatures while maintaining the magnetic properties of the powder core.
Solution Approach 2:
The invention uses a composite outer coating material combining polyamideimide-modified epoxy resin with specific additives. This composite structure provides both high-temperature resistance and magnetic property protection, resolving the contradiction between temperature endurance and magnetic reliability.
2Temperature
If a powder core is used in a high-temperature environment, then the mechanical strength is improved, but the core loss increases due to thermal denaturation
Solution Approach 1:
The invention modifies the chemical parameters of the outer coating by using a polyamideimide-modified epoxy resin with specific functional groups that provide thermal stability. This prevents core loss increase by protecting the magnetic particles from thermal denaturation even when exposed to high temperatures.
Solution Approach 2:
The outer coating acts as a sacrificial protective layer that absorbs thermal stress and prevents it from reaching the magnetic core. The coating is designed to withstand thermal degradation while protecting the core, effectively sacrificing itself to maintain core performance.
3Strength
If an outer coating is added to increase mechanical strength, then the mechanical strength is improved, but the complexity of the structure increases
Solution Approach 1:
The invention achieves the required mechanical strength by modifying the chemical parameters of the outer coating resin (using polyamideimide-modified epoxy resin with specific functional groups) rather than increasing the thickness or complexity of the coating structure. This maintains structural simplicity while providing adequate protection.
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 powder core exhibits minimal changes in magnetic properties and core loss, along with sustained mechanical strength, even after prolonged exposure to 250°C, ensuring the stability and reliability of electric and electronic components.
Implementation Method 1
the powder core of the present invention including the outer coating that contains polyethersulfone undergoes less changes in magnetic properties, in particular, core loss, since stress is rarely generated even when the powder core is put in a high temperature environment
Implementation Method 2
materials constituting the powder core may undergo thermal denaturation. Denaturation of the materials changes the magnetic properties, in particular, the core loss, of the powder core
Implementation Method 3
the compact includes the soft magnetic powder and a binding component, and the binding component may be composed of a pyrolysis residue of a binder component that contains a resin-based material
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3
AI summary
[Object] To provide a powder core that undergoes less changes in magnetic properties even when used in a high temperature environment and that has excellent mechanical properties. A powder core 1 includes a compact 1B including a soft magnetic powder, and an outer coating of the compact 1B, in which the outer coating contains polyethersulfone. A method for manufacturing the powder core 1, an electric or electronic component including the powder core 1, and an electric or electronic device having the electric or electronic component mounted therein are also provided.