CN116895458A

CN116895458A - multilayer magnetic sheet

Info

Publication number: CN116895458A
Application number: CN202310204921.9A
Authority: CN
Inventors: 宫野兴平; 栗山安男
Original assignee: Bomeilicheng Co ltd
Current assignee: Bomeilicheng Co ltd
Priority date: 2022-04-01
Filing date: 2023-03-06
Publication date: 2023-10-17

Abstract

The invention provides a multilayer magnetic sheet which is not easy to increase in man-hour. A first laminated substrate layer (310) provided with at least one layer, wherein a plurality of laminated substrates (300) formed into a strip-shaped magnetic thin layer having a short side (300S) and a long side (300L) are arranged in a plate-like manner so that the long sides are adjacent to each other; and at least one second laminated substrate layer (320) in which a plurality of laminated substrates (300) are arranged in a plate-like manner so that the long sides (300L) are adjacent to each other, and the direction in which the long sides (300L) extend is arranged so as to intersect with the direction in which the long sides (300L) in the first laminated substrate layer (310) extend.

Description

Multilayer magnetic sheet

Technical Field

The present disclosure relates to a multilayer magnetic sheet that can be used, for example, in a non-contact charging device for charging a secondary battery of an automobile.

Background

In recent years, a noncontact charging has been attracting attention, in which a transmission coil is provided on both a power feeding side and a power receiving side, and the charging is performed by power transmission by electromagnetic induction. In the noncontact charging, the magnetic flux generated by the primary transmission coil of the power feeding device generates electromotive force via the power feeding device and the case of the power receiving device, and the secondary transmission coil of the power receiving device supplies power.

Contactless charging is becoming popular for electronic devices such as tablet information terminals, music players, smartphones, mobile phones, and the like. The noncontact charging is a technique applicable to electronic devices, electric vehicles, and unmanned aerial vehicles other than those described above. And is also applicable to a truck such as a forklift, an AGV (Automated Guided Vehicle: intelligent transfer robot), a railroad, a road-surface trolley, and the like.

In the noncontact charging, in order to improve the power transmission efficiency, a magnetic sheet may be provided as a coil yoke on the opposite side of a contact surface of a transmission coil with a power feeding device and a power receiving device. The magnetic sheet thus arranged has a function as a magnetic shielding material for preventing leakage of magnetic flux during charging, a function as a yoke member for returning magnetic flux generated by the coil during charging, and the like.

As a method for producing the magnetic sheet, various methods have been proposed (for example, refer to patent documents 1 to 3). Patent documents 1 to 3 disclose a manufacturing method including the steps of: a strip of a thin plate-like magnetic material, an amorphous alloy, or a nanocrystalline alloy (hereinafter also referred to as "alloy strip") or the like included in a magnetic sheet for the purpose of increasing the Q value or reducing the eddy current loss is divided into a plurality of pieces.

In comparison with electronic devices such as smart phones, when used for non-contact charging of electric vehicles and the like, it is difficult to dispose the primary coil and the secondary coil close to each other. For example, it is necessary to electromagnetically couple the primary coil and the secondary coil in a state where a large interval exists.

The electric power to be transmitted between the primary coil and the secondary coil needs to be large. Specifically, the current flowing to the primary coil also increases, and the magnetic flux between the primary coil and the secondary coil needs to be increased.

Therefore, the primary coil and the secondary coil are larger, and there is a problem that the magnetic sheet used in electronic devices such as smart phones is insufficient in size. Further, since the magnetic flux becomes large, there is a problem that the magnetic flux is liable to leak to other devices.

The alloy ribbon included in the magnetic sheet has a ribbon-like elongated shape. The dimension, i.e., the width, of the alloy ribbon in the direction orthogonal to the longitudinal direction has a problem of being narrow for non-contact charging used in electric vehicles and the like.

In contrast, a technique is also known in which a plurality of alloy strips are arranged in a plate shape, and a plurality of alloy strips arranged in a plate shape are further overlapped in the thickness direction (for example, refer to patent document 4). In the technique described in patent document 4, the width of the surface on which the alloy ribbon is disposed is also easily increased.

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open No. 2008-112830

Patent document 2: japanese patent application laid-open No. 2015-505166

Patent document 3: international publication No. 2020-235642

Patent document 4: japanese patent application laid-open No. 2019-522355

Disclosure of Invention

Problems to be solved by the invention

The technique described in patent document 4 is a method of stacking alloy ribbons of a single layer. Therefore, there is a problem in that a magnetic sheet (also referred to as a multi-layer magnetic sheet) in which alloy thin strips of 15 or more layers are stacked has a large number of man-hours.

The present disclosure provides a multilayer magnetic sheet in which man-hours are not easily increased.

Means for solving the problems

The multilayer magnetic sheet of the present disclosure is provided with: at least one first laminated base layer in which a plurality of laminated bases each having a strip-like magnetic thin layer formed in a short side and a long side are arranged in a plate shape so that the long sides are adjacent to each other; and at least one second laminated substrate layer in which the plurality of laminated substrates are arranged in a plate shape so that the long sides thereof are adjacent to each other, and in which the direction in which the long sides extend is arranged so as to intersect with the direction in which the long sides extend in the first laminated substrate layer.

According to the multilayer magnetic sheet of the present disclosure, the multilayer magnetic sheet is configured by stacking, in the thickness direction, the first laminated base layer and the second laminated base layer, in which the plurality of laminated bases in which two or more magnetic thin strips are laminated are arranged in the shape of a plate. Since the first laminated base layer and the second laminated base layer are stacked in the thickness direction, man-hours are less likely to increase than those of a structure in which magnetic thin strips are stacked in an aligned manner.

The second laminated base layer is different from the first laminated base layer with respect to the direction in which the long side of the magnetic thin strip extends. More preferably 90 degrees apart. In other words, when viewed from the lamination direction, the gaps (also referred to as magnetic gaps) of the magnetic thin strips in the second lamination base layer are not aligned (also referred to as discontinuous) with respect to the first lamination base layer. Since the magnetic gap is discontinuous when viewed from the lamination direction, deterioration of the magnetic characteristics of the multilayer magnetic sheet is easily prevented.

The effects of the invention are as follows.

According to the multilayer magnetic sheet of the present disclosure, since the first laminated base layer and the second laminated base layer are stacked in the thickness direction, the number of man-hours at the time of manufacturing is less likely to become large than a structure in which the magnetic thin strips are stacked in an aligned manner.

Drawings

Fig. 1 is a top view illustrating the configuration of a multilayer magnetic sheet of the present disclosure.

Fig. 2 is a sectional view taken along line II-II illustrating the construction of a multilayer magnetic sheet.

Fig. 3 is an enlarged partial cross-sectional view illustrating the positional relationship of the upper and lower first laminated base layers.

Fig. 4 is an enlarged partial cross-sectional view illustrating the positional relationship of the upper and lower second laminated base layers.

Fig. 5 is an enlarged partial cross-sectional view illustrating the structure of the laminated substrate.

Fig. 6 is a partially enlarged cross-sectional view illustrating the structure of the adhesive layer 10 and the magnetic thin tape 20.

Fig. 7 is a schematic diagram illustrating a method of manufacturing a magnetic sheet.

Fig. 8 is a cross-sectional view illustrating the structure of a laminate supplied from a first unreeling roller.

Fig. 9 is a cross-sectional view illustrating the structure of the laminate after being fed from the first unreeling roller and peeled off the resin sheet.

Fig. 10 is a sectional view illustrating the structure of a magnetic thin tape supplied from a second unreeling roller.

Fig. 11 is a cross-sectional view illustrating a state in which the magnetic thin tape is adhered to the adhesive layer by the adhesion roller.

Fig. 12 is a cross-sectional view illustrating a state in which a crack is formed in a magnetic thin strip by a crack roller.

Fig. 13 is a schematic diagram illustrating a method of manufacturing a laminated substrate.

Fig. 14 is a cross-sectional view illustrating the structure of the laminated substrate.

Fig. 15 is a cross-sectional view illustrating the configuration of the multilayer magnetic sheet of the present disclosure.

Fig. 16 is a schematic view illustrating a state in which the first laminated base and the second laminated base are overlapped in the thickness direction.

Symbol description

10-adhesive layer, 11-support, 11A-first side, 11B-second side, 12-adhesive, 20-magnetic ribbon, 22-die, 300-laminated substrate, 300L-long side, 300S-short side, 310-first laminated substrate layer, 320-second laminated substrate layer, 400, 410-multilayer magnetic sheet, 401-first laminated end, 402-second laminated end.

Detailed Description

First embodiment

A multi-layered magnetic sheet 400 according to a first embodiment of the present disclosure will be described with reference to fig. 1 to 14. The multilayer magnetic sheet 400 of the present embodiment is used for a noncontact charging device. The power supply device can be used for a power supply device of a charging device and a power receiving device.

In this embodiment, the multilayer magnetic sheet 400 is applied to a case where non-contact charging is performed for a device having a power consumption larger than that of an information processing device such as a smart phone or an electronic device. For example, the present invention is applied to the multilayer magnetic sheet 400 for non-contact charging of a mobile body such as an automobile. In addition, the multilayer magnetic sheet 400 can also be used for noncontact charging of information processing apparatuses, electronic apparatuses, and the like.

Fig. 1 is a plan view illustrating the construction of a multilayer magnetic sheet 400. Fig. 2 is a cross-sectional view taken along line II-II illustrating the construction of a multilayer magnetic sheet 400.

As shown in fig. 1 and 2, the multilayer magnetic sheet 400 has a first laminated base layer 310 and a second laminated base layer 320 in which a plurality of laminated bases 300 formed in a strip shape are arranged in a plate shape. The first laminated base layer 310 and the second laminated base layer 320 are alternately stacked in the thickness direction.

The first laminated base layer 310 and the second laminated base layer 320 have the same structure. The first laminated base layer 310 and the second laminated base layer 320 are arranged in different directions when the multilayer magnetic sheet 400 is formed.

The thickness direction is also referred to as the direction in which the first laminated base layer 310 and the second laminated base layer 320 are laminated. The laminated substrate 300 constituting the first laminated substrate layer 310 and the second laminated substrate layer 320 has a strip-like or rectangular shape having two long sides 300L and two short sides 300S.

As shown in fig. 1, the multilayer magnetic sheet 400 has a plate-like or sheet-like shape formed into a rectangular shape in a plan view. The plurality of laminated substrates 300 constituting the first laminated substrate layer 310 and the second laminated substrate layer 320 are arranged so that the long sides 300L are adjacent to each other, and are arranged in a direction in which the short sides 300S extend. The interval between the laminated substrates 300 arranged in the direction in which the short sides 300S extend is preferably 0mm or more and 5mm or less.

The laminated base 300 constituting the first laminated base layer 310 and the second laminated base layer 320 is preferably arranged in a number of two or more and 20 or less in the direction in which the short side 300S extends. In addition, 20 or more may be arranged. In this embodiment, an example will be described in which 14 laminated substrates 300 are arranged.

The present embodiment will be described with reference to an example in which one laminated substrate 300 is disposed in the direction in which the long side 300L extends. The number of the laminated substrates 300 arranged in the direction along which the long sides 300L extend may be more than 1.

In this embodiment, an example will be described in which the length L in the direction in which the long side 300L of the laminated base 300 extends is in the range of 100mm to 1000mm, and the width Wr in the direction in which the short side 300S extends is in the range of 10mm to 100 mm. The length L of the laminated base 300 in the direction in which the long side 300L extends may be out of the above range, and the width Wr of the laminated base 300 in the direction in which the short side 300S extends may be out of the above range.

In this embodiment, an example will be described in which the multilayer magnetic sheet 400 has a length L of 100mm or more and 1000mm or less and a width Ws of 100mm or more and 1000mm or less.

Here, the length L is a dimension in a direction in which the long side 300L of the laminated base 300 in the first laminated base layer 310 constituting the multilayer magnetic sheet 400 extends, and the width Ws is a dimension in a direction in which the short side 300S of the laminated base 300 in the first laminated base layer 310 extends. The length L of the multilayer magnetic sheet 400 may be outside the above range, and the width Ws may be outside the above range. The end portions of the multilayer magnetic sheet 400 may be cut to obtain a multilayer magnetic sheet 400 having a desired size.

As shown in fig. 2, the multilayer magnetic sheet 400 has a structure in which the first laminated base layer 310 and the second laminated base layer 320 are alternately overlapped in the thickness direction in a cross section. The multilayer magnetic sheet 400 is provided with a resin sheet 15. The resin sheet 15 is a film-like member formed using resin and disposed at a first lamination end 401 and a second lamination end 402, which are outer end portions in the thickness direction.

The resin sheet 15 may not be laminated on the first lamination end 401 or the second lamination end 402. The magnetic thin tape 20 may be exposed, for example, an amorphous alloy thin tape, a nanocrystalline alloy thin tape, a metal foil of another magnetic material, aluminum, or the like, a resin sheet, or the like may be attached to the first lamination end portion 401 or the second lamination end portion 402.

The total number of the first laminated base layer 310 and the second laminated base layer 320, which are stacked in the thickness direction of the multilayer magnetic sheet 400, is preferably two or more and 20 or less. In the present embodiment, there is a structure in which 3 first laminated base layers 310 and 2 second laminated base layers 320 are alternately overlapped in the thickness direction. In other words, 5 laminated substrates 300 are overlapped in the thickness direction. The number of stacked substrates 300 may be less than 5 or more than 5. The number of laminated substrates 300 stacked in the thickness direction of the multilayer magnetic sheet 400 may be larger than 20.

In the structure in which the first laminated base layer 310 and the second laminated base layer 320 are alternately stacked in the thickness direction, as shown in fig. 2, the layers may be alternately stacked every 1 layer, or may be a structure having a combination of at least one group of the first laminated base layer 310 and the second laminated base layer 320, and the layers in the same direction may be continuous in the other layers.

As shown in fig. 3, in the upper first laminated base layer 310 and the lower first laminated base layer 310 arranged with the second laminated base layer 320 interposed therebetween, the position of the long side of the upper first laminated base layer 310 and the position of the long side of the lower first laminated base layer are also preferably separated by 0.5mm or more in the direction in which the short side extends. Thus, the magnetic gap can be prevented from being continuous at the position where the laminated substrates of the first laminated substrate layer 310 and the laminated substrate of the second laminated substrate layer 320 cross each other, and the magnetic gap can be further prevented from being continuously formed in addition to being arranged so as to cross each other.

As shown in fig. 4, in the upper second laminate base layer 320 and the lower second laminate base layer 320 disposed with the first laminate base layer 310 interposed therebetween, the position of the long side of the upper second laminate base layer 320 and the position of the long side of the lower second laminate base layer 320 are also preferably separated by 0.5mm or more in the direction in which the short side extends. Thus, the magnetic gap can be prevented from being continuous at the position where the laminated substrates of the first laminated substrate layer 310 and the laminated substrate of the second laminated substrate layer 320 cross each other, and the magnetic gap can be further prevented from being continuously formed in addition to being arranged so as to cross each other.

The first laminate base layer 310 and the second laminate base layer 320 are laminated such that the direction in which the long side 300L of the first laminate base layer 310 extends intersects the direction in which the long side 300L of the second laminate base layer 320 extends. More preferably, the layers are stacked so that the intersecting angle is 90±1 degrees.

Fig. 5 is an enlarged partial cross-sectional view illustrating the structure of the laminated substrate 300.

The laminated substrate 300 has a multilayer structure in which a plurality of adhesive layers 10 and a plurality of magnetic thin strips 20 are alternately laminated. In this embodiment, as shown in fig. 5, an example of a multilayer structure having 6 adhesive layers 10 and 5 magnetic thin strips 20 alternately stacked is described.

Specifically, the magnetic tape has a multilayer structure in which the adhesive layer 10, the magnetic thin tape 20, and the adhesive layer 10 are laminated in this order.

The number of the magnetic thin tapes 20 included in the laminated substrate 300 may be 5 layers as described above, or may be any number of 2 layers or more other than 5 layers. Preferably 3 or more layers, more preferably 4 or more layers, and even more preferably 5 or more layers. The upper limit may be any layer as long as it can be manufactured. For example, in the case of using the manufacturing apparatus described in fig. 13, it is preferable that two or more layers and 20 layers or less are used.

The total of the stacked magnetic thin strips 20 in the multilayer magnetic sheet 400 is preferably 10 or more layers, and more preferably 15 or more layers. The total of the laminated magnetic thin tapes 20 is preferably 200 layers or less.

Two adhesive layers 10 are continuously laminated at positions adjacent to the laminated base 300. Further, two adhesive layers 10 may be laminated on other portions. The adhesive layer 10 may be laminated with 3 or more layers, but the adhesive layer 10 is preferably laminated with two or less layers because the entire thickness is thicker. The resin sheets 15 are laminated one by one on each of the laminated substrates 300 disposed at the first lamination end 401 and the second lamination end 402. In other words, the multilayer magnetic sheet 400 is provided with two resin sheets 15 in total. The resin sheet 15 is adhered to the outermost adhesive layer 10.

As shown in fig. 6, the adhesive layer 10 is a member to which the magnetic thin tape 20 is attached. The adhesive layer 10 is a member formed in an elongated shape, for example, a film-like member formed in a rectangular shape. The adhesive layer 10 is mainly provided with a support 11 and an adhesive 12.

The support 11 is a strip-shaped film member formed in an elongated shape, and is, for example, a rectangular film member. The support 11 is formed using a resin material having flexibility. As the resin material, polyethylene terephthalate (PET) is used.

The adhesive 12 is provided on the first surface 11A and the second surface 11B of the support 11 in a film or layer form.

The adhesive 12 can be, for example, a pressure-sensitive adhesive. For example, a known adhesive such as an acrylic adhesive, a silicone adhesive, a urethane adhesive, a synthetic rubber, or a natural rubber can be used as the adhesive 12. An acrylic adhesive is preferable as the adhesive 12 because it has excellent heat resistance and moisture resistance and a wide range of materials that can be adhered.

The adhesive 12 is provided in a layer form on the first surface 11A and the second surface 11B of the support 11. In the present embodiment, the description will be given of an example in which the adhesive 12 is provided on the entire first surface 11A and the second surface 11B of the support 11.

The magnetic thin tape 20 is a strip-shaped thin tape formed into an elongated shape using a material having magnetic properties. A crack 21 is formed in the magnetic thin strip 20. The magnetic ribbon 20 is divided into a plurality of small pieces 22 by a crack 21. In other words, the magnetic ribbon 20 includes a plurality of platelets 22. The crack 21 is a magnetic gap formed in the magnetic thin strip 20, and includes, for example, a crack and/or a split of the magnetic thin strip 20.

By forming the crack 21 in the magnetic thin strip 20, the Q value can be easily improved when the multilayer magnetic sheet 400 is used as a magnetic material for an inductor. In addition, when the multilayer magnetic sheet 400 is used as a shielding magnetic material, it is easy to cut off the current path of the magnetic thin strip 20, thereby reducing eddy current loss.

As a material for forming the magnetic thin strip 20, an alloy having an alloy composition of Fe-based or Co-based can be used, and a nanocrystalline alloy or an amorphous alloy can be used. The magnetic thin ribbon 20 is particularly preferably a thin ribbon formed of a nanocrystalline alloy (hereinafter, also referred to as "nanocrystalline alloy thin ribbon").

As the nanocrystalline alloy ribbon, a nanocrystalline alloy ribbon obtained by subjecting an amorphous alloy ribbon capable of nanocrystalline to a heat treatment for nanocrystalline can be used. In the heat treatment for nanocrystalline, it is preferable to perform the heat treatment for nanocrystalline in a state where tension is applied to the nanocrystalline-capable amorphous alloy ribbon. The thin ribbon formed of an amorphous alloy is also referred to as an amorphous alloy ribbon or an amorphous alloy ribbon.

The thin ribbon of nanocrystalline alloy preferably has a composition represented by the general formula below.

A general formula: (Fe) _1－a M _a ) _{100－x－y－z－α－β－γ} Cu _x Si _y B _z M’ _α M” _β X _γ (atomic%)

In the above general formula, M is Co and/or Ni, M 'is at least one element selected from the group consisting of Nb, mo, ta, ti, zr, hf, V, cr, mn and W, M' is at least one element selected from the group consisting of Al, a platinum group element, sc, a rare earth element, zn, sn and Re, X is at least one element selected from the group consisting of C, ge, P, ga, sb, in, be and As, and a, X, y, z, alpha, beta and gamma satisfy 0.ltoreq.a.ltoreq.0.5, 0.1.ltoreq.x.ltoreq.3, 0.ltoreq.y.ltoreq.30, 0.ltoreq.z.ltoreq.25, 5.ltoreq.y+z.ltoreq.30, 0.ltoreq.alpha.ltoreq.20, 0.ltoreq.beta.ltoreq.20 and 0.ltoreq.γltoreq.20, respectively.

In the general formula, a, x, y, z, alpha, beta and gamma are preferably 0.ltoreq.a.ltoreq.0.1, 0.7.ltoreq.x.ltoreq.1.3, 12.ltoreq.y.ltoreq.17, 5.ltoreq.z.ltoreq.10, 1.5.ltoreq.alpha.ltoreq.5, 0.ltoreq.beta.ltoreq.1 and 0.ltoreq.gamma.ltoreq.1 respectively.

In the present embodiment, an example will be described in which the magnetic thin ribbon 20 is a thin ribbon of Fe-Cu-Nb-Si-B-based nanocrystalline alloy (FT-3 manufactured by Hitachi Metal Co., ltd.). The magnetic thin ribbon 20 may be a nanocrystalline alloy thin ribbon having other compositions represented by the above general formula, or an amorphous alloy thin ribbon.

In the case where the magnetic thin ribbon 20 is a nanocrystalline alloy thin ribbon, it is mechanically brittle as compared to the case where the magnetic thin ribbon 20 is an amorphous alloy thin ribbon. When the magnetic thin ribbon 20 is a nanocrystalline alloy ribbon, the crack 21 can be formed with a small external force when the external force is directly applied to the magnetic thin ribbon 20 to form the crack 21.

In the case where the magnetic thin ribbon 20 is a nanocrystalline alloy thin ribbon, the crack 21 can be formed without substantially forming irregularities on the surface of the magnetic thin ribbon 20. Therefore, the planar state of the magnetic thin tape 20 can be made good. The shape of the magnetic thin tape 20 is less changed with time after the magnetic thin tape 20 is bonded to the adhesive layer 10 to form the laminated substrate 300. The change of the magnetic properties of the laminated substrate 300 and the magnetic thin strip 20 with time can be suppressed.

As the magnetic thin strip 20, for example, an alloy thin strip having a thickness of 100 μm or less manufactured by roll quenching can be used. The thickness of the magnetic thin tape 20 is preferably 50 μm or less, more preferably 30 μm or less, further preferably 25 μm or less, and particularly preferably 20 μm or less. Further, if the thickness is small, the handling of the magnetic thin tape 20 becomes difficult, and therefore the thickness of the magnetic thin tape 20 is preferably 5 μm or more, more preferably 10 μm or more.

The magnetic ribbon 20 is adhered to the adhesive 12 of the adhesive layer 10. In the present embodiment, the magnetic thin tape 20 is bonded to the adhesive 12 provided on the first surface 11A of the adhesive layer 10. The magnetic thin tape 20 and the adhesive layer 10 have shapes satisfying the following relationship.

The width A-width B is less than or equal to 0.2mm and less than or equal to 3mm

The width a is a dimension associated with the adhesive layer 10, and more preferably a dimension associated with a region of the adhesive layer 10 where the adhesive 12 that adheres the magnetic thin tape 20 is disposed. Width B is the dimension associated with magnetic ribbon 20. In addition, in the case where the adhesive 12 is provided on the entire surface of the support 11 of the adhesive layer 10, the width a is a dimension related to the adhesive layer 10 or the support 11.

Here, the lower limit of the (width A-width B) is preferably 0.5mm, more preferably 1.0mm. The upper limit of the width A-width B is preferably 2.5mm, more preferably 2.0mm.

Also, the magnetic thin tape 20 and the adhesive layer 10 are preferably configured to satisfy the relationship of other formulas.

Gap a of 0mm < and gap b of 0mm <

The gap a and the gap b are distances from the end of the adhesive layer 10 to the end of the magnetic thin tape 20. Specifically, the gap a is a distance from the first adhesive layer end 10X of the adhesive layer 10 to the first thin strip end 20X of the magnetic thin strip 20. The gap b is the distance from the second adhesive layer end 10Y of the adhesive layer 10 to the second ribbon end 20Y of the magnetic ribbon 20.

The first thin strip end 20X is the end on the same side as the first adhesive layer end 10X in the magnetic thin strip 20. The second adhesive layer end portion 10Y is an end portion of the adhesive layer 10 on the opposite side of the first adhesive layer end portion 10X. The second ribbon end 20Y is the same side end as the second adhesive layer end 10Y in the magnetic ribbon 20.

The width a, the width B, the gap a, and the gap B are dimensions in a direction intersecting the longitudinal direction of the laminated base 300, more preferably, in a direction orthogonal to the longitudinal direction of the laminated base 300. The longitudinal direction of the laminated substrate 300 is the same as the longitudinal direction of the adhesive layer 10. The longitudinal direction of the laminated base 300 is the same as the longitudinal direction of the magnetic thin strip 20.

In the present embodiment, an example of the length of the magnetic thin tape 20 in the longitudinal direction of 20000m is applied, and a method of manufacturing the magnetic sheet 100 and the laminated substrate 300 according to the present embodiment will be described below. The present invention is described as being applied to an example in which the width a, which is a dimension related to the adhesive layer 10 or the support 11, is 32mm, the width B, which is a dimension related to the magnetic thin tape 20, is 30mm, and the width a-width B is 2 mm.

The resin sheet 15 is a film-like member formed using a resin, and is also described as a protective film, a release film, or a liner. The resin sheet 15 is a member for protecting the magnetic thin tape 20, the laminated substrate 300, and the multilayer magnetic sheet 400.

The resin sheet 15 has a function of suppressing an unnecessary increase in cracks 21 (or cracks connecting a plurality of cracks 21 to each other in a mesh shape) described below due to an unexpected external force applied to the magnetic thin tape 20. Further, the magnetic thin tape 20 has a function of suppressing the falling-off of the small pieces 22 and a function of suppressing the rust of the magnetic thin tape 20.

Further, the resin sheet 15 has a function of suppressing occurrence of unnecessary deformation when the multilayer magnetic sheet 400 is processed into a predetermined shape. As an unnecessary deformation, surface irregularities and the like can be exemplified. The resin sheet 15 may be laminated together with the adhesive layer 10 as described above, or may be laminated as a single body.

The resin sheet 15 is preferably a film-like member formed using a resin, and more preferably a member formed using a resin having elasticity. If the resin sheet 15 is a member formed using resin, the generation of irregularities on the surface of the magnetic thin tape 20 can be easily suppressed by the elastic force of the resin sheet 15.

Even if irregularities are generated on the surface of the magnetic thin tape 20, the irregularities of the magnetic thin tape 20 are easily flattened by the elastic force of the resin sheet 15. The planar state of the magnetic thin tape 20 can be set to a good state with less irregularities. It is easy to reduce the temporal variation of the magnetic characteristics of the multilayer magnetic sheet 400.

The resin sheet 15 may be a resin having a lower limit of tensile elastic modulus of 0.1 GPa. When the tensile elastic modulus of the resin is 0.1GPa or more, the above-mentioned effects can be easily and sufficiently obtained. The lower limit of the tensile elastic modulus is preferably 0.5GPa, more preferably 1.0GPa.

The upper limit of the tensile elastic modulus of the resin is preferably 10GPa. If the pressure exceeds 10GPa, deformation of the alloy ribbon may be suppressed when forming a crack 21 described below. The upper limit of the tensile elastic modulus is preferably 9GPa, more preferably 8GPa.

The thickness of the resin sheet 15 is preferably 1 μm or more and 100 μm or less. If the thickness of the resin sheet 15 increases, the multilayer magnetic sheet 400 is less likely to deform. It may be difficult to dispose the multilayer magnetic sheet 400 along a curved or bent surface.

If the thickness of the resin sheet 15 is less than 1 μm, the resin sheet 15 is easily deformed. Handling of the resin sheet 15 becomes difficult, and the function of supporting the magnetic thin tape 20 by the resin sheet 15 may not be sufficiently obtained. When the resin sheet 15 is a protective film, the strength of the resin sheet 15 may be weakened, and the function of protecting the magnetic thin tape 20 or the like may be insufficient.

As the resin, for example, polyethylene terephthalate (PET), polyimide, polyetherimide, polyethylene naphthalate, polypropylene, polyethylene, polystyrene, polycarbonate, polysulfone, polyether ketone, polyvinyl chloride, polyvinyl alcohol, fluorine resin, acrylic resin, cellulose, and the like can be used as the resin sheet 15. From the viewpoints of heat resistance and dielectric loss, polyamide and polyimide are particularly preferable as the resin forming the resin sheet 15.

Next, a method for manufacturing the multilayer magnetic sheet 400 according to the present embodiment will be described with reference to fig. 7 to 14. First, a method for manufacturing the magnetic sheet 100 constituting the multilayer magnetic sheet 400 and the laminated base 300 will be described.

Fig. 7 is a schematic diagram illustrating a method of manufacturing the magnetic sheet 100.

The magnetic sheet 100 is a magnetic sheet constituting the laminated base 300 and the multilayer magnetic sheet 400. The magnetic sheet 100 is manufactured using the manufacturing apparatus 500 shown in fig. 7. The manufacturing apparatus 500 is mainly provided with a first unreeling roller 510, a first winding roller 520, a second unreeling roller 530, a pasting roller 540, a cracking roller 550, a flattening roller 560, and a third winding roller 570 from upstream to downstream in the manufacturing process. The manufacturing apparatus 500 may further include a plurality of guide rollers 580. The guide roller 580 may be disposed at a position not described, as necessary.

Fig. 8 is a cross-sectional view illustrating the structure of the laminate supplied from the first unreeling roller 510.

As shown in fig. 8, a laminate in which the resin sheets 15 are laminated on the first surface 11A and the second surface 11B of the adhesive layer 10 is wound around the first unwinding roller 510. The resin sheet 15 disposed on the first surface 11A is a protective sheet, and the resin sheet 15 disposed on the second surface 11B is also referred to as a gasket. The resin sheet 15 disposed on the first surface 11A is a sheet having a thickness smaller than that of the resin sheet 15 disposed on the second surface 11B.

Fig. 9 is a cross-sectional view illustrating the structure of the laminate after being fed from the first unreeling roller 510 and the resin sheet 15 being peeled off.

As shown in fig. 9, the resin sheet 15 disposed on the first surface 11A of the laminate discharged from the first unwind roller 510 is peeled off. As shown in fig. 7, the peeled resin sheet 15 is wound around a first winding roller 520.

Fig. 10 is a sectional view illustrating the structure of the magnetic thin tape 20 supplied from the second unreeling roller 530.

The laminate of the resin sheets 15 placed on the first surface 11A after being peeled off is guided to the laminating roller 540 by a plurality of guide rollers 580. The magnetic thin tape 20 discharged from the second unreeling roller 530 is also guided to the pasting roller 540. As shown in fig. 10, the crack 21 is not formed in the magnetic thin tape 20 guided to the pasting roller 540.

Here, a method of manufacturing the magnetic thin tape 20 discharged from the second unreeling roller 530 will be described. For example, a case where the magnetic thin ribbon 20 is a nanocrystalline alloy will be described. The magnetic thin strip 20 is manufactured by a manufacturing method including the steps of: quenching the alloy melt to obtain an amorphous alloy ribbon capable of nano crystallization; and a heat treatment step of forming fine crystal grains by heat-treating the amorphous alloy ribbon at a temperature equal to or higher than the crystallization start temperature.

The quenching is performed by a single roll method in which a molten metal is discharged onto a rotating cooling roll to be quenched and solidified. The magnetic thin strip 20 has a long strip shape that is elongated in the direction along the direction of rotation of the cooling roller. The length of the magnetic thin tape 20 in the longitudinal direction can be, for example, 20000m.

The temperature of the heat treatment varies depending on the alloy composition, but is usually 450 ℃ or higher. The fine crystal grains are, for example, fe having a body-centered cubic lattice structure in which Si or the like is dissolved. The analysis of the fine crystal grains can be performed using an X-ray diffraction and transmission electron microscope.

In the nanocrystalline alloy, at least 50% by volume of the nanocrystalline alloy is occupied by fine crystal grains having an average grain diameter of 100nm or less as measured in the largest dimension. The portions of the nanocrystalline alloy other than the fine crystal grains are mainly amorphous. The proportion of fine grains may be substantially 100% by volume.

Fig. 11 is a cross-sectional view illustrating a state in which the magnetic thin tape 20 is adhered to the adhesive layer 10 by the adhesion roller 540.

As shown in fig. 7, the adhesive roller 540 presses and adheres the magnetic thin tape 20 to the laminate from which the resin sheet 15 is peeled off. Specifically, the laminate and the magnetic thin tape 20 are guided between two rollers disposed opposite to each other, and the magnetic thin tape 20 is pressed against and bonded to the first surface 11A of the adhesive layer 10 using 2 rollers as shown in fig. 11.

The magnetic thin tape 20 may be arranged such that the center coincides with the center of the adhesive layer 10 in the width direction, or may be arranged such that the centers are separated. In this case, the relationship between 0mm < gap a and 0mm < gap b is satisfied (see fig. 6). As shown in fig. 7, the laminate to which the magnetic thin tape 20 is bonded is guided from the bonding roller 540 to the cracking roller 550.

Fig. 12 is a cross-sectional view illustrating a state in which the crack roller 550 forms the crack 21 in the magnetic thin strip 20.

The crack roller 550 forms the crack 21 in the magnetic thin tape 20 adhered to the adhesive layer 10. Specifically, the laminate having the magnetic thin tape 20 bonded thereto is guided between two rollers disposed opposite to each other, and the protruding roller of the two rollers is pressed against the magnetic thin tape 20, whereby a crack 21 is formed as shown in fig. 12.

The roller not provided with the protrusions of the two rollers is disposed on the laminate side from which the resin sheet 15 is peeled. The magnetic thin strip 20 formed with the crack 21 includes a plurality of small pieces 22. A plurality of die 22 are adhered to the adhesive layer 10.

Here, the structure of the cracking roller 550 will be described. The cracking roller 550 is a roller in which a plurality of convex members are arranged on the peripheral surface. The tip of the end of the convex member of the cracking roller 550 may be flat, tapered, or inverted tapered or cylindrical with a concave center. The plurality of convex members may be arranged regularly or irregularly.

The cracks 21 are continuously formed in the magnetic thin tape 20 by pressing the long magnetic thin tape 20 against the crack rollers 550 or passing the long magnetic thin tape 20 between the two crack rollers 550. The convex members of the crack roller 550 are pressed against a plurality of portions of the surface of the magnetic thin tape 20, and a plurality of cracks 21 are formed in the magnetic thin tape 20.

In forming the crack using the crack roller 550, it is further preferable to form a crack connecting the plurality of cracks 21 to each other in a mesh shape. Specifically, it is preferable that the step of forming the plurality of cracks 21 by pressing the crack roller 550 against the magnetic thin tape 20 is performed after forming the plurality of cracks 21, and then the plurality of cracks 21 are connected to each other in a mesh shape.

For example, after the crack roller 550 directly applies an external force to the magnetic thin strip 20 to form the crack 21, a second external force may be applied by bending or winding the magnetic thin strip 20 to form a crack connecting the plurality of cracks 21 to each other in a mesh shape. The cracks connecting the cracks 21 to each other (magnetic gaps connecting the cracks to each other) form the cracks 21 as the starting points of brittle fracture and/or crack fracture.

In the step of forming the plurality of cracks 21 connected to each other in a mesh shape, the second external force described above may not be applied. In the case where the second external force is not applied, in the process of forming the plurality of cracks 21, cracks connecting the plurality of cracks 21 to each other in a mesh shape are formed.

The laminate guided from the cracking roller 550 to the flattening roller 560 is subjected to a flattening process by the flattening roller 560. The flattening roller 560 is also referred to as a truing roller.

Specifically, the laminate is guided between two rollers disposed opposite to each other of the flattening roller 560, and is sandwiched and pressed between the two rollers. Thereby, the surface of the magnetic thin strip 20 having the crack 21 formed thereon is flattened.

The laminated body subjected to the planarization treatment becomes the magnetic sheet 100. The magnetic sheet 100 is guided to the third winding roller 570 via the guide roller 580. The magnetic sheet 100 is wound around the third winding roller 570.

Fig. 13 is a schematic diagram illustrating a method of manufacturing the laminated substrate 300.

The laminated base 300 is manufactured using the manufacturing apparatus 600 shown in fig. 13. Fig. 13 shows a manufacturing apparatus 600 for manufacturing the laminated substrate 300 including the 5-layer magnetic thin tape 20.

The manufacturing apparatus 600 mainly includes a supply roller 601, a resin sheet winding roller 602, a first magnetic sheet unwinding roller 611, a first winding roller 612, a first bonding roller 613, a second magnetic sheet unwinding roller 621, a second winding roller 622, a second bonding roller 623, a third magnetic sheet unwinding roller 631, a third winding roller 632, a third bonding roller 633, a fourth magnetic sheet unwinding roller 641, a fourth winding roller 642, a fourth bonding roller 643, a fifth magnetic sheet unwinding roller 651, a fifth bonding roller 653, a flattening roller 663, and a laminated substrate winding roller 670, from upstream to downstream in the manufacturing process. The manufacturing apparatus 600 may further include a plurality of guide rollers 680. The guide roller 680 may be disposed at a position not described, if necessary.

The manufacturing apparatus 600 may manufacture the laminated substrate 300 having the number of the magnetic thin strips 20 of 2 or more layers and 20 or less layers. In this case, the number of the first magnetic sheet unreeling rollers 611 and the like is changed according to the number of the magnetic thin tapes 20. The number of layers of the magnetic thin tape 20 may be appropriately determined. However, when the laminated substrate 300 is wound, if the number of layers of the magnetic thin tape 20 is large, it may be difficult to wind or a shape defect may occur during winding. Therefore, in the case of winding the laminated substrate 300, the number of layers is preferably 15 or less. More preferably 10 layers or less. The number of layers of the magnetic thin tape 20 is preferably 3 or more, more preferably 4 or more, and still more preferably 5 or more. Further, although the laminated substrate 300 having more than 20 layers can be produced, the device is too large, and therefore, 20 layers or less are preferable.

As shown in fig. 8, a laminate in which resin sheets 15 are laminated on first surface 11A and second surface 11B of adhesive layer 10 is wound around supply roller 601.

As shown in fig. 9, the resin sheet 15 disposed on the first surface 11A of the laminate discharged from the supply roller 601 is peeled off. As shown in fig. 13, the peeled resin sheet 15 is wound around a resin sheet winding roller 602.

The laminate of the resin sheets 15 placed on the first surface 11A after being peeled off is guided to the first bonding roller 613 by the guide roller 680. The magnetic sheet 100 discharged from the first magnetic sheet unreeling roller 611 is also guided to the first attaching roller 613.

The first bonding roller 613 presses and bonds the magnetic sheet 100 to the laminate from which the resin sheet 15 has been peeled. Specifically, the laminate and the magnetic sheet 100 are guided between two rollers disposed opposite to each other, and the magnetic thin tape 20 of the magnetic sheet 100 is pressed against and bonded to the first surface 11A of the adhesive layer 10 by using the two rollers.

The bonded magnetic thin tape 20 of the magnetic sheet 100 may be arranged such that the center coincides with the center of the adhesive layer 10 in the width direction, or may be arranged such that the centers are separated. In this case, the relationship between 0mm < gap a and 0mm < gap b is satisfied (see fig. 6).

The resin sheet 15 of the magnetic sheet 100 bonded by the first bonding roller 613 is peeled off from the magnetic sheet 100 and wound around the first winding roller 612. The laminate of the resin sheet 15 wound around the first winding roller 612 is guided to the second attaching roller 623. The magnetic sheet 100 discharged from the second magnetic sheet unreeling roller 621 is also guided to the second attaching roller 623.

The second bonding roller 623 presses and bonds the magnetic sheet 100 to the laminate led out from the first bonding roller 613. The bonded magnetic thin tape 20 of the magnetic sheet 100 may be arranged so that the center thereof coincides with the center of the adhesive layer 10 of the laminate led out from the first bonding roller 613 in the width direction, or may be arranged so that the centers are separated.

In this case, the relationship between 0mm < gap a and 0mm < gap b is satisfied (see fig. 6). The resin sheet 15 of the magnetic sheet 100 bonded by the second bonding roller 623 is peeled off from the magnetic sheet 100 and wound around the second winding roller 622.

The laminate after the resin sheet 15 is wound around the second winding roller 622 is guided to the third bonding roller 633. The magnetic sheet 100 discharged from the third magnetic sheet unreeling roller 631 is also guided to the third pasting roller 633.

The third bonding roller 633 presses and bonds the magnetic sheet 100 to the laminate led out from the second bonding roller 623. The bonded magnetic thin tape 20 of the magnetic sheet 100 may be arranged so that the center coincides with the center of the adhesive layer 10 of the laminate led out from the second bonding roller 623 in the width direction, or may be arranged so as to be separated from the center.

In this case, the relationship between 0mm < gap a and 0mm < gap b is satisfied (see fig. 6). The resin sheet 15 of the magnetic sheet 100 bonded by the third bonding roller 633 is peeled off from the magnetic sheet 100 and wound around the third winding roller 632.

The laminate after the resin sheet 15 is wound around the third winding roller 632 is guided to the fourth adhering roller 643. The magnetic sheet 100 discharged from the fourth magnetic sheet unwinding roller 641 is also guided to the fourth pasting roller 643.

The fourth bonding roller 643 presses and bonds the magnetic sheet 100 to the laminate led out from the third bonding roller 633. The bonded magnetic thin tape 20 of the magnetic sheet 100 may be arranged so that the center coincides with the center of the adhesive layer 10 of the laminate, which is led out from the third bonding roller 633, in the width direction, or may be arranged so as to be separated from the center.

In this case, the relationship between 0mm < gap a and 0mm < gap b is satisfied (see fig. 6). The resin sheet 15 of the magnetic sheet 100 bonded by the fourth bonding roller 643 is peeled off from the magnetic sheet 100 and wound around the fourth winding roller 642.

The laminate after the resin sheet 15 is wound around the fourth winding roller 642 is guided to the fifth pasting roller 653. The magnetic sheet 100 discharged from the fifth magnetic sheet unreeling roller 651 is also guided to the fifth attaching roller 653.

The fifth bonding roller 653 presses and bonds the magnetic sheet 100 to the laminate that is fed out from the fourth bonding roller 643. The bonded magnetic thin tape 20 of the magnetic sheet 100 may be arranged so that the center thereof coincides with the center of the adhesive layer 10 of the laminate led out from the fourth bonding roller 643 in the width direction, or may be arranged so that the centers are separated.

In this case, the relationship between 0mm < gap a and 0mm < gap b is satisfied (see fig. 6). The laminate guided from the fifth pasting roller 653 to the flattening roller 663 is subjected to a flattening process by the flattening roller 663.

As described above, the relationship between the magnetic thin tape 20 and the adhesive layer 10 is preferably configured to satisfy the relationship of 0mm < gap a and 0mm < gap b (see fig. 6). However, positional relationship may deviate during the lamination process of the magnetic sheet 100 and the laminate. When this positional relationship is deviated, for example, the gap a is negative in the relationship between the magnetic thin tape 20 and the adhesive layer 10. That is, on one surface side of the magnetic thin tape 20, the end portion of the magnetic thin tape 20 may protrude from the end portion of the adhesive layer 10. Even when the end of the magnetic thin tape 20 protrudes from the end of the adhesive layer 10 on one surface side of the magnetic thin tape 20, the magnetic thin tape 20 can remain adhered to the adhesive layer 10 if the relationship between the magnetic thin tape 20 and the adhesive layer 10 is arranged in advance so as to satisfy the relationship of 0mm < gap a and 0mm < gap b on the other surface side of the magnetic thin tape 20 (see fig. 6).

Fig. 14 is a cross-sectional view illustrating the structure of the laminated substrate 300.

The laminate after the planarization treatment becomes the laminate base 300 shown in fig. 14. The laminate substrate 300 is guided to the laminate substrate winding roller 670 via the guide roller 680. The laminate substrate 300 is wound around a laminate substrate winding roller 670.

The laminate substrate 300 may be continuously cut into a desired length in addition to the method of winding around the laminate substrate winding roller 670.

As shown in fig. 1, the laminated substrate 300 manufactured by the manufacturing apparatus 600 is cut so that the dimension in the direction in which the long side 300L extends is the length L. The cut laminated base 300 is arranged in a direction in which the short side 300S extends and has a plate shape, and a first laminated base layer 310 and a second laminated base layer 320 are formed. The number of the arrangement of the laminated substrates 300 can be exemplified as 14.

The first laminated base layer 310 and the second laminated base layer 320 are stacked in the thickness direction as shown in fig. 2. For example, 3 first laminated base layers 310 and 2 second laminated base layers 320 are overlapped in the thickness direction to manufacture the multilayer magnetic sheet 400. When overlapped in the thickness direction, the resin sheets 15 are peeled off from the first laminated base layer 310 and the second laminated base layer 320, and the adhesive layers 10 are adhered to each other.

According to the multilayer magnetic sheet 400 having the above-described structure, the multilayer magnetic sheet 400 is configured by stacking the first laminated base layer 310 and the second laminated base layer 320 in the thickness direction in a wide width, wherein the plurality of laminated bases 300 in which the magnetic thin strips 20 are stacked in a range of two or more layers and 20 layers or less are arranged in a plate shape in the first laminated base layer 310 and the second laminated base layer 320. Since the first laminated base layer 310 and the second laminated base layer 320 are stacked in the thickness direction, man-hours are less likely to increase than those of a structure in which the magnetic thin strips 20 are stacked in an aligned manner.

The second laminated base layer 320 is different from the first laminated base layer 310 with respect to the direction in which the long side 300L of the magnetic thin strip 20 extends. More preferably 90 degrees apart. In other words, when viewed from the lamination direction, the gaps (also referred to as magnetic gaps) of the magnetic thin strips 20 in the second lamination base layer 320 are not aligned (also referred to as discontinuous) with respect to the first lamination base layer 310. Since the magnetic gap is discontinuous when viewed from the lamination direction, deterioration of the magnetic characteristics of the multilayer magnetic sheet 400 is easily prevented.

Further, by adjusting the positions of the long sides between the plurality of first laminated base layers 310 and the positions of the long sides between the plurality of second laminated base layers 320, the laminated base layers are disposed so as to intersect with each other, and thus the magnetic gap can be further prevented from being continuously formed.

The multilayer magnetic sheet 400 can be formed to a desired size by setting the width of the multilayer magnetic sheet 400 to 100mm or more and 1000mm or less and the length to 100mm or more and 1000mm or less.

By setting the magnetic thin ribbon 20 to be an amorphous alloy thin ribbon or a nanocrystalline alloy thin ribbon, the magnetic thin ribbon 20 can be made to be a soft magnetic thin ribbon. Also, an alloy can be used to form the magnetic thin strip 20.

The magnetic thin strip 20 is made to include a plurality of small pieces 22, so that the characteristics of the multilayer magnetic sheet 400 are easily improved. Specifically, when the multilayer magnetic sheet 400 is used as a magnetic material for an inductor, improvement in Q value is easily achieved. In addition, when the multilayer magnetic sheet 400 is used as a shielding magnetic material, it is easy to cut off the current path of the magnetic thin strip 20, thereby reducing eddy current loss.

The adhesive layer 10 is provided between the adjacent magnetic thin strips 20, and the adjacent magnetic thin strips 20 can be held by the adhesive layer 10. Specifically, the adhesive 12 provided on the first surface 11A of the support 11 is adhered to one of the adjacent magnetic thin strips 20, and the adhesive 12 provided on the second surface 11B is adhered to the other of the adjacent magnetic thin strips 20.

Two adhesive layers 10 are provided between the adjacent magnetic thin strips 20, and a plurality of plate-shaped laminated substrates 300 are easily stacked in the thickness direction.

The resin sheet 15 is provided at the first lamination end 401 or the second lamination end 402, so that the manufactured multilayer magnetic sheet 400 can be easily protected. For example, when the manufactured multilayer magnetic sheet 400 is transported, the adhesive layer 10 and the magnetic thin tape 20 are easily prevented from being damaged.

Further, an amorphous alloy ribbon, a nanocrystalline alloy ribbon, a metal foil of another magnetic material, aluminum, or the like, a resin sheet, or the like may be adhered to the first lamination end portion 401.

The width a of the region of the adhesive layer 10 where the adhesive 12 is provided is wider than the width B of the magnetic thin tape 20. When the magnetic thin tape 20 is attached to the adhesive layer 10, even if the adhesive layer 10 and the magnetic thin tape 20 are bent, the adhesive 12 of the adhesive layer 10 is easily disposed on the entire surface of the magnetic thin tape 20.

When the value obtained by subtracting the width B from the width a is 0.2mm or more, it is easy to prevent the occurrence of the portion where the adhesive 12 is not disposed in the magnetic thin tape 20 when the magnetic thin tape 20 is adhered to the adhesive layer 10. When the value obtained by subtracting the width B from the width a is 3mm or less, it is easy to prevent the portion of the magnetic sheet 100 where the magnetic thin strip 20 is not disposed from becoming large. Further, when the magnetic sheets are arranged in parallel, it is easy to prevent the interval (magnetic gap) between the magnetic thin strips 20 from becoming large.

The width a and the width B are in relation to each other in the present disclosure, and thus have an effect of easily disposing the adhesive 12 of the adhesive layer 10 on the entire surface of the magnetic thin tape 20 and easily suppressing the separation of the small pieces 22 formed by dividing the magnetic thin tape 20.

Second embodiment

A multi-layered magnetic sheet 410 according to a second embodiment of the present disclosure will be described with reference to fig. 15 and 16. The basic structure of the multilayer magnetic sheet of the present embodiment is the same as that of the first embodiment, but differs from the first embodiment in that the first laminated base and the second laminated base are arranged to be stacked in the thickness direction. Therefore, in the present embodiment, only the different configurations will be described with reference to fig. 15 and 16, and the description of the same configurations will be omitted.

Fig. 15 is a cross-sectional view illustrating the construction of the multilayer magnetic sheet 410.

As shown in fig. 15, the multilayer magnetic sheet 410 has at least one first laminated base 310 and at least one second laminated base 320. The multilayer magnetic sheet 410 has a structure in which the first laminated base 310 and the second laminated base 320 are arranged to overlap each other in the thickness direction.

The first and second laminated substrates 310 and 320 may be alternately stacked. Also, a plurality of first laminated substrates 310 or second laminated substrates 320 may be stacked continuously.

The first laminated base 310 and the second laminated base 320 have the same structure. The first laminated substrate 310 and the second laminated substrate 320 are arranged in different directions when the multilayer magnetic sheet 410 is formed. The arrangement direction is described below.

In the case where a plurality of first laminated substrates 310 are used, the number of layers of each magnetic thin strip 20 may be the same or a combination of different numbers of layers may be used. In the case where a plurality of second laminated substrates 320 are used, the number of layers of each magnetic thin strip 20 may be the same or a combination of different numbers of layers may be used. The number of layers of the magnetic thin strip 20 in the first laminated base 310 and the second laminated base 320 may be the same or a combination of different numbers of layers.

Note that, when it is not necessary to distinguish between the first laminated base 310 and the second laminated base 320, the laminated base 300 is also described. The thickness direction is also referred to as the direction in which the plurality of laminated substrates 300 are laminated.

The multilayer magnetic sheet 410 is provided with a resin sheet 15. The resin sheet 15 is a film-like member formed of resin and disposed at a first lamination end 401 and a second lamination end 402, which are outer ends in the thickness direction.

The total number of the first laminated base 310 and the second laminated base 320 of the multilayer magnetic sheet 410 overlapped in the thickness direction is preferably two or more and 20 or less. In the present embodiment, there is a structure in which 3 first laminated substrates 310 and 2 second laminated substrates 320 are alternately overlapped in the thickness direction. The number of laminated substrates 300 stacked in the thickness direction of the multilayer magnetic sheet 410 may be larger than 20.

The total of the stacked magnetic thin strips 20 in the multilayer magnetic sheet 410 is preferably 10 or more layers, more preferably 15 or more layers, and even more preferably 25 or more layers. The total of the laminated magnetic thin tapes 20 is preferably 200 layers or less.

The laminated substrate 300 has a multilayer structure in which a plurality of adhesive layers 10 and a plurality of magnetic thin strips 20 are alternately laminated. In this embodiment, an example of a multilayer structure having 6 adhesive layers 10 and 5 magnetic thin strips 20 alternately stacked will be described.

The number of the magnetic thin tapes 20 included in the laminated substrate 300 may be 5 layers as described above, or may be any number of 2 layers or more and 20 layers or less other than 5 layers.

The number of the magnetic thin strips 20 included in the laminated substrate 300 may be 20 or more. The number of the magnetic thin tapes 20 included in the laminated substrate 300 is preferably 3 or more, more preferably 4 or more, and even more preferably 5 or more. And, it is preferably 15 layers or less, more preferably 10 layers or less.

Two adhesive layers 10 are continuously laminated at a position where the laminated base 300 is adjacent, for example, a position where the first laminated base 310 is adjacent to the second laminated base 320, and a position where two first laminated bases 310 or second laminated bases 320 are continuous.

Further, two adhesive layers 10 may be laminated on other portions. The adhesive layer 10 may be laminated with three or more layers, but is preferably laminated with two or less layers because the entire thickness is thicker.

The resin sheets 15 are laminated one by one on each of the laminated substrates 300 disposed at the first lamination end 401 and the second lamination end 402. In the case shown in fig. 15, a single resin sheet 15 is laminated on the first lamination base 310 disposed at the first lamination end 401 and the second lamination end 402. In other words, the multilayer magnetic sheet 410 is provided with two resin sheets 15 in total. The resin sheet 15 is adhered to the outermost adhesive layer 10.

Fig. 16 is a schematic diagram illustrating a state in which the first laminated base 310 and the second laminated base 320 are stacked in the thickness direction.

As shown in fig. 16, the magnetic thin tape 20 included in the first laminated base 310 and the second laminated base 320 is provided with a roll contact surface 20A and a free solidification surface 20B.

The plurality of magnetic thin strips 20 in the first laminated substrate 310 are arranged in the same direction from the roll contact surface 20A toward the free solidification surface 20B, that is, in the arrangement direction. The plurality of magnetic thin strips 20 in the second laminated substrate 320 are arranged in the same direction from the roll contact surface 20A toward the free solidification surface 20B, that is, in the arrangement direction.

The roller contact surface 20A is a surface of the magnetic thin strip 20 that contacts the cooling roller when manufactured by the single roller method. The free solidification surface 20B is a surface of the magnetic thin strip 20 that is not in contact with a cooling roller when manufactured by the single-roller method. In other words, the free solidifying surface 20B is a surface of the magnetic thin strip 20 on the opposite side of the roller contact surface 20A.

The arrangement direction in the first laminated base 310 constituting the multilayer magnetic sheet 410 is opposite to the arrangement direction in the second laminated base 320. Specifically, the direction of the magnetic thin tape 20 from the roller contact surface 20A toward the free solidification surface 20B is opposite in the first laminated base 310 and the second laminated base 320.

Next, a method for manufacturing the multilayer magnetic sheet 410 according to the present embodiment will be described. In addition, the method from the method of manufacturing the magnetic sheet 100 to the method of manufacturing the laminated base 300 in the method of manufacturing the multilayer magnetic sheet 410 is the same as that of the first embodiment, and therefore, the description thereof is omitted.

As shown in fig. 15 and 16, the laminated base 300 manufactured by the manufacturing apparatus 600 is overlapped in the thickness direction so that the arrangement direction in the first laminated base 310 is opposite to the arrangement direction in the second laminated base 320. For example, 3 first laminated substrates 310 and 2 second laminated substrates 320 are alternately overlapped in the thickness direction to manufacture the multilayer magnetic sheet 410. The total of the magnetic thin tapes 20 included in the multilayer magnetic sheet 410 is preferably 15 layers or more. When overlapped in the thickness direction, the resin sheet 15 is peeled off from the first laminated base 310 and the second laminated base 320, and the adhesive layers 10 are adhered to each other.

The laminated substrates 300 manufactured by the manufacturing apparatus 600 are arranged in the same direction in the first laminated substrate 310 and the second laminated substrate 320, and may be stacked in a manner opposite to each other in the arrangement direction when the first laminated substrate 310 and the second laminated substrate 320 are stacked.

Example (example)

A plurality of magnetic thin strips 20 of Fe-Cu-Nb-Si-B-based nanocrystalline alloy 20 (FT-3, hitachi Metal Co., ltd.) having a width of 30mm were used to produce a laminated substrate 300 having 5 layers, a width of 32mm and a length of 100mm as shown in FIG. 14. The thickness of one end and the thickness of the other end of the multilayer magnetic sheet were measured in 10 of the laminated substrates 300, and the difference was calculated. The difference between the thickness of one end and the thickness of the other end was 7 μm on average. One end corresponds to one end of the magnetic thin tape 20 in the width direction, and the other end corresponds to the other end of the magnetic thin tape 20 in the width direction. The width direction of the magnetic thin tape 20 is also a direction perpendicular to the longitudinal direction of the magnetic thin tape 20.

Next, as shown in fig. 15, 5 laminated substrates 300 were laminated to produce a multilayer magnetic sheet 410.

In the embodiment, 5 laminated substrates 300 are laminated so that the arrangement direction, which is the direction from the roll contact surface 20A toward the free solidification surface 20B, is alternately opposite.

In the comparative example, the lamination was performed so that all directions from the roller contact surface 20A toward the free solidification surface 20B, i.e., the arrangement directions, were the same.

4 samples were prepared in each of examples and comparative examples, and the thickness at one end and the thickness at the other end were measured, and the difference was calculated to obtain an average value. Then, the permeability μ' and Q value were measured, and the average value was obtained. The results are shown in Table 1. As shown in table 1, in the examples, the difference in thickness between one end and the other end was greatly reduced. Although the permeability μ' and the Q value are substantially equal, the embodiment slightly improves.

TABLE 1

	The difference between the thickness of one end and the thickness of the other end	μ'	μ″	Q
					Examples	5μm	1077	70.6	15.3
Comparative example	32μm	1070	72.8	14.8

The measurement methods of the magnetic permeability μ' and Q are as follows.

Method for measuring permeability μ' and Q

The multilayer magnetic sheets 410 of examples and comparative examples were punched out in the form of rings having an outer diameter of 20mm and an inner diameter of 9mm, and were used as evaluation samples. Using a sample for evaluation, the OSC level was set to 0.03V by an impedance analyzer (E4990A, measuring jig: 16454a, manufactured by deutsche technology), and impedance (Z) and inductance (LS) of the series equivalent circuit were measured at a frequency of 84kHz at a temperature of 25 ℃ and calculated based on the following formula.

μ'＝2π×LS/(μ0×t×n×ln(OD/ID))

Z: absolute value of impedance

t: thickness of thin strip (m)

n: layer number

Mu 0: vacuum permeability (4×pi×10) ^－7 H/m)

OD: outer diameter (m)

ID: inner diameter (m)

Q＝μ'/μ”

1 (1)

μr＝2π×Z/(2π×μ0×f×t×n×ln(OD/ID))

f: frequency (Hz)

According to the multilayer magnetic sheet 410 of the above-described structure, the arrangement direction in the first laminated base 310 constituting the multilayer magnetic sheet 410 is opposite to the arrangement direction in the second laminated base 320. Specifically, the direction of the magnetic thin tape 20 from the roller contact surface 20A toward the free solidification surface 20B is opposite in the first laminated base 310 and the second laminated base 320.

Even if the thickness of the magnetic thin tape 20 is not uniform, the thickness of the entire magnetic thin tape 20 included is likely to become uniform when viewed as the multilayer magnetic sheet 410 by reversing the arrangement direction in the first laminated base 310 and the second laminated base 320. In other words, the dimension in the thickness direction is easily brought into a predetermined range.

Specifically, by reversing the arrangement direction of the magnetic thin tape 20 in the first laminated base 310 and the second laminated base 320, a portion of the magnetic thin tape 20 having a larger size in the thickness direction can be easily overlapped with a smaller portion than in the case of not reversing. In other words, dimensional deviations in the thickness direction of the magnetic thin strip 20 are easily absorbed.

The case where the thickness dimension of one end in the width direction of the magnetic thin tape 20 is large and the thickness dimension of the other end on the opposite side is small is as follows. The magnetic thin strips 20 are arranged in opposite directions, and one end of the magnetic thin strip 20 in the first laminated base 310 overlaps the other end of the magnetic thin strip 20 in the second laminated base 320. Therefore, dimensional deviation of the magnetic thin strip 20 in the thickness direction is absorbed. As a result, deterioration of the function as the multilayer magnetic sheet 410 due to dimensional deviation in the thickness direction of the magnetic thin strip 20 is easily suppressed.

Further, the dimensional deviation in the thickness direction of the entire magnetic thin strip 20 included in the multilayer magnetic sheet 410 is easily brought within a predetermined range. For example, when the predetermined ranges are the same, it is easy to increase the allowable range of the thickness dimension required for the magnetic thin strip 20 alone. For example, in the case of the single magnetic thin strip 20 having a thickness of 16 μm, the magnetic thin strip 20 having a thickness dimension difference in the width direction of 2 μm or less is easily relaxed to a value larger than 2 μm.

In other words, even if the magnetic thin strip 20 having a large allowable range of the thickness dimension is used, the dimensional deviation of the entire magnetic thin strip 20 included in the multilayer magnetic sheet 410 in the thickness direction is easily brought into a predetermined range.

Therefore, the magnetic thin strip 20 having a thickness dimension larger than the allowable range and not usable for the production of the multilayer magnetic sheet 410 can be used in the production. For example, deterioration of yield in manufacturing the multilayer magnetic sheet 410 is easily suppressed.

In addition, the process of managing the thickness of the magnetic thin strip 20 and the process of sorting in the production of the multilayer magnetic sheet 410 can be simplified or eliminated. In other words, an increase in the manufacturing process of the multilayer magnetic sheet 410 is easily suppressed.

The technical scope of the present disclosure is not limited to the above-described embodiments, and various modifications can be made without departing from the spirit of the present disclosure. For example, the multilayer magnetic sheets 400 and 410 of the present disclosure can be used as an induction element or the like.

Claims

1. A multilayer magnetic sheet comprising:

at least one first laminated base layer in which a plurality of laminated bases each formed into a strip-like magnetic thin layer having a short side and a long side are arranged in a plate-like manner so that the long sides are adjacent to each other;

and at least one second laminated substrate layer in which the plurality of laminated substrates are arranged in a plate shape so that the long sides thereof are adjacent to each other, and in which the direction in which the long sides of the second laminated substrate layer extend is arranged so as to intersect with the direction in which the long sides of the first laminated substrate layer extend.

2. The multilayer magnetic sheet according to claim 1, wherein,

the laminated body layer comprises an upper first laminated body layer and a lower first laminated body layer through the second laminated body layer,

the position of the long side in the upper first laminated base layer is separated from the position of the long side in the lower first laminated base layer by 0.5mm or more in the direction in which the short side extends.

3. The multilayer magnetic sheet according to claim 1, wherein,

the multilayer magnetic sheet has a width of 100mm to 1000mm, and a length of 100mm to 1000 mm.

4. The multilayer magnetic sheet according to claim 1, wherein,

the magnetic ribbon is an amorphous alloy ribbon or a nanocrystalline alloy ribbon.

5. The multilayer magnetic sheet according to claim 1, wherein,

the magnetic ribbon is a nanocrystalline alloy ribbon comprising a plurality of platelets.

6. The multilayer magnetic sheet according to claim 1, wherein,

an adhesive layer is provided between the adjacent magnetic thin strips in the laminated substrate, the adhesive layer having a support formed in a strip shape and an adhesive provided on the first surface and the second surface of the support.

7. The multilayer magnetic sheet according to claim 1, wherein,

in the direction in which the laminated substrates are laminated, two adhesive layers each having a support formed in a belt shape and an adhesive provided on the first surface and the second surface of the support are disposed between the adjacent laminated substrates.

8. The multilayer magnetic sheet according to claim 1, wherein,

In the direction in which the laminated substrates are laminated,

the magnetic thin tape at the first lamination end or the second lamination end opposite to the first lamination end is provided with an adhesive layer and a resin sheet,

the adhesive layer has a support formed in a band shape and an adhesive provided on the first surface and the second surface of the support,

the resin sheet is a film-like member formed using a resin, and is bonded to the adhesive layer.

9. The multilayer magnetic sheet according to any one of claims 6 to 8, wherein,

when the width a is the dimension of the adhesive layer in the direction intersecting the longitudinal direction of the adhesive layer and the width B is the dimension of the magnetic thin tape in the direction intersecting the longitudinal direction of the magnetic thin tape,

meets the relation that the width is less than or equal to 0.2mm and less than or equal to 3 mm.