Seiko Epson has been granted a patent for a method of manufacturing a dust core. The process involves coating soft magnetic powder with an insulating body containing aluminum-oxygen compounds, subjecting it to energy and specific atmospheric conditions, and then pressing it to form a molded product. GlobalData’s report on Seiko Epson gives a 360-degree view of the company including its patenting strategy. Buy the report here.
According to GlobalData’s company profile on Seiko Epson, E-transaction user interfaces was a key innovation area identified from patents. Seiko Epson's grant share as of June 2024 was 46%. Grant share is based on the ratio of number of grants to total number of patents.
Method for manufacturing a dust core with insulating coating
The granted patent US12046415B2 outlines a method for manufacturing a dust core, which involves several key steps to enhance the properties of soft magnetic powder. The process begins with coating the particles of soft magnetic powder with an insulating body that contains a compound with an aluminum-oxygen bond, such as trimethoxyaluminum, triethoxyaluminum, or polymethylaluminoxane. Following this, the coated particles are subjected to irradiation with ultraviolet rays or treated with ionized gas or ozone gas. The next step requires exposing the treated soft magnetic powder to a controlled atmosphere with a dew point between -30° C. and 15° C. Finally, the method includes pressing the soft magnetic powder to form a molded product under a pressure range of 20 MPa to 400 MPa.
Additionally, the patent claims further enhancements to the manufacturing process. One such enhancement involves firing the molded product at temperatures between 100° C. and 400° C. to improve its properties. The method also allows for the application of vibration to the soft magnetic powder either before or during the irradiation or gas treatment steps, which may aid in achieving better coating and treatment results. Notably, the soft magnetic powder used in this method can possess an amorphous phase, potentially contributing to the performance characteristics of the final dust core product. This comprehensive approach aims to optimize the manufacturing process and enhance the functional attributes of the dust core.
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