Soft Magnetic Resin Molding Composition for High Fillability
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Solution Overview
Problem
There is a trade-off between increasing the magnetic permeability of magnetic materials and improving fillability into a mold, as higher concentrations of soft magnetic particles in resin molding materials increase viscosity, making it difficult to fill the mold effectively during molding processes like compression molding.
Innovation Solution
A resin molding material comprising soft magnetic particles with a content of at least 96% by mass, silica fine powder with an average particle diameter of 0.1 μm to 2.0 μm, and a thermosetting resin, which allows for high magnetic permeability and excellent mold fillability by optimizing particle distribution and fluidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filling amount of soft magnetic particles is increased to improve magnetic permeability, then magnetic characteristics are improved, but viscosity of the resin molding material is increased and fillability into the mold is lowered
Solution Approach 1:
The patent changes the particle size parameter of silica from conventional larger sizes to fine powder with average particle diameter of 0.1 μm to 2.0 μm. This parameter change allows the silica to effectively reduce viscosity and improve fillability even when soft magnetic particles are present at high concentrations (96% by mass or more), thereby resolving the contradiction between maintaining high magnetic permeability and ensuring good mold fillability.
Solution Approach 2:
The patent creates a composite molding material system combining soft magnetic particles (96% by mass or more), silica fine powder (0.1 μm to 2.0 μm average diameter), and thermosetting resin. This specific composite formulation with precisely controlled composition and particle size distribution enables both high magnetic permeability and excellent fillability, resolving the technical contradiction through optimized material composition.
2Reliability
If the content of soft magnetic particles is increased to improve magnetic characteristics, then magnetic permeability is improved, but the viscosity of the resin molding material increases
Solution Approach 1:
The patent applies parameter change by using silica fine powder with average particle diameter of 0.1 μm to 2.0 μm, which is significantly finer than conventional silica. This fine particle size allows the silica to effectively lubricate and reduce viscosity of the molding material, enabling high soft magnetic particle content (96% by mass or more) to be achieved while maintaining low enough viscosity for good processability.
Solution Approach 2:
The patent develops a specific composite material system where silica fine powder (0.1 μm to 2.0 μm) acts as a viscosity-reducing agent in combination with soft magnetic particles (96% by mass or more) and thermosetting resin. This composite formulation resolves the contradiction between high magnetic particle content and low viscosity by using precisely controlled particle size and composition.
Data Source
AI summary
A resin molding material of the present invention contains (A) soft magnetic particles, (B) a silica fine powder having an average particle diameter of equal to or more than 0.1 μm and equal to or less than 2.0 μm, and (C) a thermosetting resin, in which a content of the soft magnetic particles (A) is equal to or more than 96% by mass, and a content of the silica fine powder (B) is equal to or less than 1.5% by mass.