摘要
Composite magnetic films, made of magnetic powder and a polymer substrate, hold great promise for industrial applications such as inductors for integrated circuits and advanced packaging. However, inadequate powder dispersion can lower solid content and weaken magnetic properties. This study incorporates carbonyl iron (CI) powder into epoxy resin to create composite films, using silane coupling agent (SCA) and oleic acid as dispersants to evaluate and compare their dispersion effectiveness. Both dispersants increased the CI powder content in the epoxy from less than 40 vol% to an impressive 50 vol%, with SCA achieving markedly better dispersion uniformity and enhancing magnetorheological effects, allowing for precise control of the CI particle arrangement within the films. This improvement in solid content and particle arrangement resulted in enhanced saturation magnetization and relative permeability. Finite element method simulations further validated the magnetization differences between films with varying degrees of CI particle dispersion and arrangement.