Stepped Ferrite Powder for Resin Adhesion Without Particle Dropout

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Solution Overview

Problem

The detachment of ferrite particles from composite articles during processing reduces the smoothness of the surface, which is attributed to the smooth surfaces of spherical or polyhedral ferrite particles leading to poor adhesion with resins.

Innovation Solution

Ferrite powder with a stepped feature on the surface, characterized by polygonal contours, is used to enhance adhesion to resins, preventing particle detachment without impairing formability and filling ability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If spherical or polyhedral ferrite powder is used, then flowability and filling rate are improved, but adhesion to resin deteriorates causing particle detachment

Engineering Contradiction:

Improvefilling rateVSAvoidadhesion

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention applies local quality by creating stepped features only on the surface of the ferrite particles while maintaining their overall spherical or polyhedral shape. This localized surface modification enhances adhesion at the particle-resin interface without affecting the bulk particle properties that determine flowability and filling rate. The stepped features provide localized anchoring points for the resin while the overall particle geometry remains optimized for processing.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The stepped features are pre-formed on the ferrite particle surfaces before composite fabrication. This preliminary action of creating surface irregularities ensures that when the resin is applied, it can immediately bond to the stepped structures, preventing particle detachment during subsequent processing and use. The adhesion enhancement is built-in rather than added later.

Inventive Principle:

Principle #10Preliminary action

2Quantity of substance

If particle size is increased, then filling rate improves, but flowability deteriorates causing gate clogging

Engineering Contradiction:

Improveparticle sizeVSAvoidflowability

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The invention maintains spherical or polyhedral particle shapes even for larger particle sizes. The curved surfaces and rounded geometries of spherical/polyhedral particles reduce inter-particle friction and improve flow characteristics compared to irregularly shaped particles of the same size. This allows larger particles to maintain good flowability while achieving high filling rates.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS12595188B2Ferrite powder, ferrite resin composite material, and electromagnetic shielding material, electronic material, or electronic component

Publication Date: 2026.04.07 POWDERTECH CO LTD

AI summary

Provided are: a ferrite powder whereby, when the ferrite powder is applied in a composite material, dropping out of ferrite particles is suppressed without moldability and filling ability being compromised; a ferrite resin composite material; and an electromagnetic shielding material, an electronic material, or an electronic component. This ferrite powder includes at least spherical or polyhedral ferrite particles in which a step structure is provided on surfaces thereof, the step structure having a polyhedral outline in the surfaces of the ferrite particles.