CN113458347A - 合金薄带、层叠芯 - Google Patents

合金薄带、层叠芯 Download PDF

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CN113458347A
CN113458347A CN202110330634.3A CN202110330634A CN113458347A CN 113458347 A CN113458347 A CN 113458347A CN 202110330634 A CN202110330634 A CN 202110330634A CN 113458347 A CN113458347 A CN 113458347A
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alloy
strip
alloy thin
recess
adhesive layer
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中畑功
塚原拓也
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TDK Corp
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TDK Corp
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    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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Abstract

本发明的合金薄带(100)是包含以金属作为主成分的合金薄带，在至少一个主面(100a)具有凹部(101)，凹部的深度D1是平均厚度D的5％以上且75％以下。

Description

合金薄带、层叠芯
技术领域
本发明涉及一种合金薄带、以及使用合金薄带形成的层叠芯。
本申请基于2020年3月31日在日本申请的日本特愿2020-063266号主张优先权，并将其内容引用至此。
背景技术
在如层叠功能性薄带的构造体，例如层叠磁性芯中，在芯中以多高的密度填充作为功能层的磁性薄带，对于获得高的特性至关重要。
一般的，为提高层叠芯的占空系数，认为需要提高薄带的表面平滑性，并且使薄带彼此粘接的层(粘接层)尽可能地变薄。专利文献1公开了一种使薄带的表面平滑的技术。另外，在专利文献2中，公开了：通过将形成于薄带的辊面的气袋直径缩小至一定以下，并且抑制配置于辊上的薄带的表面粗糙度，来获得良好的磁特性。
然而，通过用于粘接薄带彼此的一般的粘接层的厚度为10μm以下，并且使接着层变薄而显著地显现出粘接强度的下降。如上所述，已知占空系数的提高与薄带间的粘接力是折衷的关系。
现有技术文献
专利文献
专利文献1：日本专利第4529106号公报
专利文献2：日本专利第4623400号公报
发明内容
发明所要解决的课题
本发明是鉴于上述情况而做出的，其目的在于提供一种合金薄带和使用该合金薄带形成的层叠芯，该合金薄带可以维持高的占空系数，并且提高隔着粘接层的与其他的构件的粘接力。
用于解决课题的方法
本发明为了解决上述技术问题，提供以下技术手段。
(1)本发明的一个方式所涉及的合金薄带是包含金属作为主成分的合金薄带，并且在至少一个主面具有凹部，所述凹部的深度为平均厚度的5％以上且75％以下。
(2)在上述(1)所述的合金薄带中，优选为，所述凹部的开口直径为10μm以上。
(3)在上述(1)或(2)中任一项所述的合金薄带中，优选为，仅在所述一个主面具有所述凹部。
(4)在上述(1)～(3)中任一项所述的合金薄带中，优选为，在从厚度方向俯视时，分布于每1mm2的所述凹部的数量为150个以下。
(5)在上述(1)～(4)中任一项所述的合金薄带中，优选为，在所述凹部的开口部，长径相对于短径的比为1.5以上。
(6)本发明的一个方式所涉及的层叠芯，其将多个上述(1)～(5)中的任一项所述的合金薄带，以夹着粘接层的方式，沿厚度方向层叠多个而成，并且隔着所述接着层相对的两个所述合金薄带中的至少一个在与所述接着层相对的面具有所述凹部。
发明的效果
在本发明的合金薄带，在隔着粘接层而与其他的构件(合金薄带)粘接的至少一个主面具有凹部。因此，较薄地形成粘接层的大部分，维持高的占空系数，但是通过仅在具有凹部的部位，使厚度局部地增大，可以实现与其他的构件的高的粘接力。因此，通过隔着粘接层而层叠多个本发明的合金薄带，可以获得维持高的占空系数并且提高层叠的合金薄带彼此的粘接力的层叠芯。
附图说明
图1A、图1B是本发明一个实施方式所涉及的合金薄带的立体图、截面图。
图2A、图2B是示出设置于图1的合金薄带的凹部的开口部的变形例的图。
图3是制造图1的合金薄带的制造装置的概略结构图。
图4A、图4B是使用图1的合金薄带形成的层叠芯的截面图。
图5是绘制本发明的比较例、实施例中的凹部的数密度和占空系数的数据的图表。
符号说明
100、100A、100B、100E……合金薄带
100a……合金薄带的一个主面
101……凹部
101a……凹部的开口部
100D……合金薄带的原料
102……腔
102a……腔的开口部
103……滚子
103a……滚子的表面
104、105、106……喷嘴
107……管
108……粘接层
110……合金薄带的制造装置
120、130……层叠芯
D……合金薄带的平均厚度
D1……凹部的深度
E……粘接层的平均厚度
EA、EB、EAB……粘接层的厚度
G1、G2……气体
R……凹部的内径
Rb……凹部的短径
Rc……凹部的长径
具体实施方式
在下文中，适当参照附图对本发明进行详细地说明。在以下的说明中使用的附图，为了容易理解本发明的特征，方便而言，有时将成为特征的部分放大表示，各构成要素的尺寸比率等有时与实际不同。以下的说明中例示的材料、尺寸等为一例，本发明不限定于这些，能够在实现本发明的效果的范围内适当变更而实施。
图1A是示意地说明本发明的一个实施方式所涉及的合金薄带100的结构的立体图。图1B是在沿包含A-A线的面切断图1A的合金薄带100的情况下的截面图。合金薄带100以Fe、Co、Ni、Si、C、B、Nb、Mo、P、Cu、V、Al、Zn、Zr、Ag、Mn、As、Sb、Cr、Bi、Hf、Ta、O、N等元素中的至少一种、或者以含有该元素的合金作为主成分的带状的合金薄膜。
合金薄膜的厚度优选为约10～40μm。如果合金薄膜的厚度小于10μm，则难以维持强度，存在破损的风险，另外，因为当试图层叠至规定的厚度时，层叠数变多，粘接层的数量增加，所以有时变得难以提高占空系数。如果合金薄膜的厚度超过40μm，则例如在用作磁性芯的情况下，存在涡电流损失增大的缺点。此外，占空系数是作为磁性体(功能层)在层叠芯的总体积之中所占的体积的比例而算出的，具体地，定义为：将“从层叠芯的外形尺寸和重量计算出的密度”除以通过阿基米德法等测量的“薄带的真实密度”的量。
作为形成层叠磁性芯时的优选材料，可以列举例如以Fe-Si-B作为主成分的Fe基非晶系薄带、以Co-Fe-Ni-Si-B作为主成分的Co基非晶系薄带、以Fe-Si-B-Nb-Cu、Fe-Nb-B-P、Fe-Si-B-Nb-Cu等作为主成分的Fe基纳米结晶系薄带。任一种材料有时也包含微量的添加元素。
合金薄带100在至少一个主面具有向内侧凹陷的一个以上的凹部(非贯通的孔)101。在本实施方式中，虽然例示出仅形成于一侧的主面100a的情况，但是凹部101也可以形成于两侧的主面。但是，以不使形成于各自的侧的凹部101彼此连通并且形成有贯通孔的方式，调整形成的凹部101的位置和深度。对于形成的凹部101的形状等而言，可以使用共聚焦激光显微镜等进行检测。
虽然对凹部的开口部101a的形状不做限制，但是出于制造上的理由，容易实现如图2A、图2B所示那样的大致楔形、大致长方形的形状，也可以根据制造条件做成其他的形状。在凹部的开口部101a，长径(最大径)Rc相对于短径(最小径)Rb的比(Rc/Rb)(长径比)优选为1.5以上。由于凹部的开口部101a的面积越大，则粘接层的厚度增加的部分越多，粘接力提高，因此，优选开口部101a的开口直径、即开口部101a的最大径和最小径的平均为10μm以上。
从制造上的观点出发，凹部101内的内径R，虽然易于与深度成比例地减小，但也可以与深度成比例地增大，也可以与深度无关而为恒定。作为内径与深度成比例地变化的凹部101，可以列举例如凹部101内的空间为大致半球状的凹部、圆锥状、棱锥状等(大致锥状)的凹部。另外，作为内径与深度无关而为恒定的凹部101，可以列举例如凹部101内的空间为圆柱状、棱柱状等(大致柱状)的凹部。凹部101的深的部分的截面积(内径)是越大的形状(如果是上述的例子，则按大致锥状<大致半球状<大致柱状的顺序)，则粘接力越大。
凹部101的深度D1优选为合金薄带100的平均厚度D的5％以上且75％以下。通过设为5％以上，可以局部地增加厚度，获得强化在该部分的粘接力的效果。在大于75％的情况下，虽然也可以获得提高粘接力的效果，但是比较显著地显现于对占空系数降低的影响。在此，使用测微计测定合金薄带100的30个部位的厚度，并且将该平均值作为合金薄带的平均厚度D。
在从合金薄带100的厚度D方向俯视时，分布于每1mm2的凹部101的数量(数密度)优选为1个以上且150个以下。即使凹部101的数密度超过150，也可以获得提高粘接力的效果，但是比较显著地显现于对占空系数降低的影响。如果凹部101的数密度超过150个，则凹部101彼此的距离变短，在凹部间缺失薄带表面，存在占空系数降低的风险。对于同一俯视图中的凹部101的分布方法，不做特别限定，虽然优选均一地分布，但根据用途，也可以在中央密集分布，也可以沿外周分布，也可以随机分布。
图3是示出合金薄带的制造装置110的一例的图。制造装置110主要由腔102、配置于腔102内的滚子103、三个喷嘴104、105、106、以及连接至腔102的侧壁的开口部102a的管107构成。
滚子103作为以通过中心C的轴作为旋转轴沿一个方向(在此为顺时针方向)旋转的技术方法发挥功能。
喷嘴104作为连接至合金薄带的原料供应源(未图示)，向旋转的滚子103的表面103a提供(滴加)液体状地熔融的合金薄带的原料(熔液)100D的技术方法发挥功能。
喷嘴105作为连接至气体G1的供应源(未图示)，在从喷嘴104提供的合金薄带的原料100D与滚子的表面103a之间，供应(注入)气体G1的技术方法发挥功能。
作为气体G1，可以使用空气、氩气、氮气、二氧化碳等的气体。注入的气体G1通过与熔融并处于高温状态下的原料100D接触而热膨胀。原料100D以在与滚子的表面103a之间夹着热膨胀的气体G1的状态，与滚子103一起旋转。原料100D在旋转的过程中固化，以紧贴于滚子表面103a的状态形成合金薄带100。
喷嘴106作为连接至气体G2的供应源(未图示)，以使固化的合金薄带100从滚子的表面103a分离的方式，向合金薄带100与滚子的表面103a之间，提供(注入)气体G2的技术方法发挥功能。作为气体G2，可以使用空气、氩气、氮气或二氧化碳等的气体。
分离的合金薄带100从开口部102a经由管107内，取出至腔102之外。取出的合金薄带100被卷绕于规定的辊并且保管。在从滚子103分离的合金薄带100E的表面，压入气体G1的空间作为凹部101而残留。
也可以将滚子的表面103a通过例如由研磨纸进行的研磨、或喷砂等的方法粗糙化，从而在表面103a设置凹凸结构。在这种情况下，容易在凹凸结构的位置处积存气体G1，容易在合金薄带100B的表面形成凹部。
例如，通过调整腔102内的压力、滚子103的旋转速度等的制造条件，可以形成具有期望的形状/尺寸并且以期望的比例分布的凹部101。腔102内的压力越高，则存在凹部101的开口直径越大，深度增加的倾向。另外，滚子103的旋转速度越大，则存在从正交于合金薄带100B的表面的方向观察到的、开口部101a的长径比增加的倾向。在本实施方式中，以至少凹部的深度为平均厚度D的5％以上且75％的方式，优选进一步以凹部101的开口直径为10μm以上的方式，更优选进一步以分布于每1mm2的凹部101的数量为150个以下的方式，调整各种制造条件。
图4A是通过以夹着粘接层108的方式重叠多个本实施方式的合金薄带100而获得的层叠芯120的截面图。作为粘接层108，可以使用已知的材料，例如，可以使用丙烯酸类粘接剂、硅树脂、丁二烯树脂、环氧树脂等材料。粘接层108的平均厚度优选为约0.5～10μm。
经由粘接层108而相对的两个合金薄带100A、100B中的至少一个在与粘接层108相对的面具有凹部101。由此，即使粘接层108使整体的平均厚度变薄，因为在凹部101处局部地增加了厚度，所以也可以维持规定的粘接力。为了遍及合金薄带100的整体均匀地维持粘接力，在从厚度D方向俯视时，优选各向同性地形成凹部101。
在此，例示出两个合金薄带100A、100B分别在粘接层108侧具有凹部101A、101B的情况。另外，尽管在此例示出凹部101A、101B以彼此不同的间距分布的情况，但是也可以以彼此相同的间距分布。
在从厚度D方向俯视时，凹部101A、101B也可以不重叠，如果重叠，则相较于凹部101仅在单侧的情况的厚度EA、EB，在该部分的粘接层108的厚度EAB增加，并且粘接力也成比例地增加。
在此，例示出层叠两个合金薄带100A、100B的情况，但是对层叠数没有限制，也可以层叠三个以上。
图4B是本实施方式的变形例所涉及的层叠芯130的截面图。相对于一个粘接层108，如果至少一个合金薄带在粘接层108侧具有凹部101，则局部地形成有超过平均厚度E的厚度EA的部分，可获得维持粘接力的效果。因此，如图4B所示，在一个合金薄带100A在粘接层108侧具有凹部101A的情况下，另一个合金薄带100C也可以不具有凹部。
如上所述，在本实施方式的合金薄带100，在隔着粘接层108而与其他的构件(合金薄带)粘接的至少一个主面100a具有凹部101。因此，虽然较薄地形成粘接层108的大部分，维持高的占空系数，但是通过仅在具有凹部101的地方使厚度局部地增大，可以实现与其他的构件的高的粘接力。因此，通过隔着粘接层108层叠多个本实施方式的合金薄带100，可以获得维持高的占空系数并且提高层叠的合金薄带100彼此的粘接力的层叠芯120。另外，在本实施方式的合金薄带100，相较于与粘接层108接触的面平坦的情况，凹部101通过发挥如抑制粘接层108的面内方向的偏离的摩擦那样的效果，可以进一步提高粘接力。
在粘接层108薄的情况下，因为粘接剂的厚度越厚，则粘接力越大，所以当以一个凹部101进行比较时，深度越深的一方粘接力越大。当从平均的粘接力来看时，可以想到相较于存在少数的深的部位，个数越多，则粘接力越高。在开口直径同等且个数也同等的情况下，可以想到平均的深度越深，则粘接力越高。
以下，通过实施例使本发明的效果更加明确。此外，本发明不限于以下的实施例，可以在不改变其要旨的情况下适当地修改并且实施。
准备在表面不具有凹部的合金薄带(比较例)以及在表面具有凹部的合金薄带(实施例1～10)，测量各个的粘接力和占空系数。实施例1～10的合金薄带中的任一个，均将凹部的开口直径(最大径和最小径的平均径)设为10μm以上，将深度设为平均厚度(此处为约20μm)的5～75％，使每1mm2的凹部的个数分别不同。
将形成于比较例、实施例1～10的合金薄带的表面(实施例1～10中为具有凹部的侧)形成粘接层，隔着该粘接层使其他的合金薄带贴合，将剥离贴合的薄带所需的力作为粘接力。测定剥离粘接层所需的粘接力，将该粘接力为0.01N/mm的情况设为A、将0.02N/mm的情况设为B、将0.03N/mm的情况设为C，将以0.04N/mm以上的力不能剥离的情况设为D进行评价。算出层叠物、层叠体的尺寸密度相对于合金薄带的理论密度的比作为占空系数。表1中总结了比较例、实施例1～10的合金薄带的每1mm2的凹部的个数、和粘接力、占空系数的关系。另外，表2中总结了实施例11～14的合金薄带的每1mm2的凹部的个数、长径比为1.5以上的凹部的比例(％)、粘接力、和占空系数的关系。
【表1】
Figure BDA0002994313670000081
Figure BDA0002994313670000091
如比较例所示可知，在不具有凹部的情况下，虽然可以获得高的占空系数，但是粘接力弱。相对于此，在实施例1中，可知，仅通过将每1mm2的凹部的个数增加一个，粘接力增加至2倍。
【表2】
Figure BDA0002994313670000092
从实施例11可知，即使仅设置很少的长径比为1.5以上的凹部，也可以实现兼具高的粘接力和高的占空系数。与此相反，从实施例13、14可知，即使设置的大部分的凹部的长径比为1.5以上，同样也可以实现兼具高的粘接力和高的占空系数。
图5是绘制出表1所示的比较例、实施例1～10中的凹部的个数与占空系数的数据的图表。图表的横轴表示开口直径为10μm以上、具有合金薄带的平均厚度的5～75％的深度的凹部的个数(mm-2)。图表的纵轴表示合金薄带的占空系数。关于占空系数可知，在每1mm2的凹部的数量是0个的情况与是1个的情况下，差别不大，而在每1mm2的凹部的数量大于150个的情况和小于150个的情况下，大幅地变化。从这些结果可知，在每1mm2的凹部的数量为150个的范围内，将合金薄带的占空系数维持在85％以上的高的值，与不具有凹部的现有技术的平坦的合金薄带相比，可以使粘接力提高3倍以上。

Claims (6)

1.一种合金薄带，其特征在于，
是包含金属作为主成分的合金薄带，
在至少一个主面具有凹部，
所述凹部的深度为平均厚度的5％以上且75％以下。
2.根据权利要求1所述的合金薄带，其特征在于，
所述凹部的开口直径为10μm以上。
3.根据权利要求1或2所述的合金薄带，其特征在于，
仅在所述一个主面具有所述凹部。
4.根据权利要求1～3中任一项所述的合金薄带，其特征在于，
在从厚度方向俯视时，分布于每1mm2的所述凹部的数量为150个以下。
5.根据权利要求1～4中任一项所述的合金薄带，其特征在于，
在所述凹部的开口部，长径相对于短径的比为1.5以上。
6.一种层叠芯，其特征在于，
将权利要求1～5中的任一项所述的合金薄带，以夹着粘接层的方式，沿厚度方向层叠多个而成，
隔着所述粘接层相对的两个所述合金薄带中的至少一个在与所述粘接层相对的面具有所述凹部。
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