Soft Magnetic Alloy Sheet Casting Without High-Temperature Sintering
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Solution Overview
Problem
Existing methods for producing soft magnetic alloy sheets for high-power and high-current applications require high-temperature sintering, which damages insulation coatings and results in increased loss, while traditional processes struggle to achieve high saturation magnetic induction strength, low loss, and high-temperature resistance.
Innovation Solution
A method involving the mixing of thermosetting resin, thermoplastic resin, and insulation-coated soft magnetic alloy powder, followed by degassing and casting-drying, to create a sheet with high saturation magnetic induction strength, low loss, and temperature resistance above 160°C, avoiding the need for high-temperature sintering and ensuring the insulation coating remains intact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature sintering is used to densify the magnetic material, then the magnetic density and saturation magnetic induction strength are improved, but the insulation coating layer is destroyed and loss increases
Solution Approach 1:
The invention changes the sintering temperature parameter from traditional high temperature (600-800°C) to low temperature (below 600°C, specifically 400-550°C), which allows the magnetic material to achieve adequate density without destroying the insulation coating layer, thereby reducing energy loss while maintaining magnetic performance
Solution Approach 2:
The invention uses a composite slurry system combining magnetic powder, insulation coating material, organic solvent, and binder, which enables low-temperature processing while maintaining both magnetic properties and insulation integrity, avoiding the need for high-temperature sintering that would damage the coating
2Ease of manufacture
If thermoplastic resin is used as binder in the slurry, then the casting process is easier, but the high-temperature resistance above 160°C cannot be achieved
Solution Approach 1:
The invention changes the binder type from thermoplastic resin to thermosetting resin, which undergoes chemical curing to form a cross-linked network structure that provides high-temperature resistance above 160°C while still enabling the casting process
Solution Approach 2:
The invention utilizes the phase transition of thermosetting resin from liquid slurry state to solid cured state through chemical curing reaction, which provides both ease of casting in liquid form and high-temperature resistance in the cured state, unlike thermoplastic resin that softens at high temperatures
3Loss of energy
If low-temperature sintering is used to preserve the insulation coating, then the magnetic density and saturation magnetic induction strength are reduced
Solution Approach 1:
The invention uses a composite slurry with optimized composition including magnetic powder, insulation coating material, and binder that achieves adequate magnetic density through low-temperature curing rather than high-temperature sintering, maintaining both low loss and acceptable magnetic performance
Solution Approach 2:
The invention changes the processing temperature parameter to low temperature range (400-550°C) and uses thermosetting resin curing to achieve sufficient magnetic density without the need for high-temperature sintering, balancing magnetic performance with insulation preservation
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 resulting soft magnetic alloy sheet achieves high magnetic storage capacity, low loss, and maintains strength and flexibility at elevated temperatures, preventing brittleness and ensuring effective performance in high-frequency applications.
Implementation Method 1
by using the high temperature curing characteristic (generally at 150-220° C.) of thermosetting resin, the magnetic sheet achieves hardening
Implementation Method 2
can reach the high temperature resistance requirements above 160° C. after being cured
Data Source
AI summary
The present application provides a soft magnetic alloy sheet, a preparation method therefor and a use thereof. The preparation method comprises the following steps: (1) mixing thermosetting resin, thermoplastic resin, a solvent, a curing agent, and soft magnetic alloy powder having insulating coating to obtain casting slurry; and (2) carrying out degassing and casting-drying treatment on the casting slurry in step (1) in sequence to obtain the soft magnetic alloy sheet.