EP2139011B1 - Magnetkern für eine antenne, verfahren zur herstellung eines magnetkerns für eine antenne und antenne - Google Patents

Magnetkern für eine antenne, verfahren zur herstellung eines magnetkerns für eine antenne und antenne Download PDF

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Publication number
EP2139011B1
EP2139011B1 EP08740203.8A EP08740203A EP2139011B1 EP 2139011 B1 EP2139011 B1 EP 2139011B1 EP 08740203 A EP08740203 A EP 08740203A EP 2139011 B1 EP2139011 B1 EP 2139011B1
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EP
European Patent Office
Prior art keywords
antenna
magnetic core
thin metal
laminate
magnetic
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EP08740203.8A
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English (en)
French (fr)
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EP2139011A4 (de
EP2139011A1 (de
Inventor
Daisuke Kishi
Nakao Moritsugu
Yoshitsugu Furui
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Proterial Ltd
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Hitachi Metals Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0233—Manufacturing of magnetic circuits made from sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15391—Elongated structures, e.g. wires
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q7/00—Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop
    • H01Q7/06—Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop with core of ferromagnetic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q7/00—Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop
    • H01Q7/06—Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop with core of ferromagnetic material
    • H01Q7/08—Ferrite rod or like elongated core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15316—Amorphous metallic alloys, e.g. glassy metals based on Co
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15383—Applying coatings thereon
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F10/00—Thin magnetic films, e.g. of one-domain structure
    • H01F10/08—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers
    • H01F10/10—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers characterised by the composition
    • H01F10/12—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers characterised by the composition being metals or alloys
    • H01F10/13—Amorphous metallic alloys, e.g. glassy metals
    • H01F10/138—Amorphous metallic alloys, e.g. glassy metals containing nanocrystallites, e.g. obtained by annealing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/02—Cores, Yokes, or armatures made from sheets

Definitions

  • the present invention relates to a bar-shaped magnetic core for an antenna using a laminate of thin metal strips having soft magnetism, and an antenna using the magnetic core for antenna, which is used for a keyless entry system for vehicles and the like.
  • antennas having a ferrite core have been used for RFID (wireless IC tag) for a keyless entry system of a vehicle or the like.
  • RFID wireless IC tag
  • ferrite is brittle, cracks occur therein even due to slight deformation.
  • a crack is generated by a shock when a key falls to the ground or when a user walks around with the key in a pocket of trousers, etc. so that properties thereof deteriorate.
  • an amorphous thin metal strip has been used for a material of the magnetic core for antenna, and the laminated amorphous thin metal strips have been used as the magnetic core.
  • JP-A-2004-166071 discloses a magnetic core for antenna in which an amorphous thin metal strip is wound around a plate bobbin and a coil is wound therearound. It discloses that the end of the magnetic core can thereby have an arbitrary curved surface and thickness, and fluctuation in transmission/reception performance of the magnetic core for antenna can be prevented.
  • An adhesive such as a resin is applied on a surface of the thin metal strip, and subsequently, the thin metal strips are pressure bonded using a hot press, etc.
  • EP-1 473 377 A1 describes a magnetic laminate which is heat-treated after cutting the substrate in both its length and its width direction.
  • a strip has been conventionally cut and subsequently stacked.
  • small sized soft magnetic strips must be stacked, and thus working efficiency is very low.
  • soft magnetic strips having a certain dimension are desirably stacked, and then, processed into a desired antenna shape.
  • an object of the present invention is to provide a magnetic core for antenna that can be manufactured in an easy process and has a high Q value (i.e. antenna properties), and to provide a high-performance antenna using the magnetic core for antenna.
  • the present invention is defined in present claim 1.
  • the subclaims relate to preferred embodiments.
  • the width direction is a direction along a short side of the magnetic core for an antenna. While the width direction may not always be perpendicular to the longitudinal direction, inclination therebetween is preferably within 20° in terms of processability and mechanical strength of products.
  • Slitting is preferably used as means of processing the continuous thin metal band.
  • the processed thin strip preferably has a width of not more than 5 mm.
  • a resin layer is preferably formed by applying a polyamic acid solution that is a precursor of a thermosetting polyimide resin, because of its excellent thermal resistance. That can be used for antennas for vehicles in particular.
  • a magnetic core for antenna having a rectangular parallelepiped shape and comprising a laminate of thin metal strips, characterized in that projections and depressions of the thin metal strips observed on a long side of a stacking surface are larger than those on a short side of the stacking surface. Disclosed is also that parallel machining marks are observed only on the stacking surface along the short side.
  • a width of the magnetic core for antenna is not more than 5 mm.
  • the magnetic core for antenna preferably has a ratio of a length in relation to a width being not less than 3.
  • the thin metal band is preferably manufactured continuously in a band having a thickness of 5 to 100 ⁇ m by the roll quenching method, or manufactured by the roll quenching method and then cut to a length of not less than 50 mm. For example, it has a preferable dimension of not less than 1000 mm 2 in area.
  • the magnetic core for antenna including a laminate of the thin metal strips
  • eddy current loss decreases and a Q value improves.
  • a thin metal band itself manufactured by the roll quenching method or the laminate of the thin metal strips is subjected to heat treatment in a magnetic field, so that induced magnetic anisotropy is given to all over the thin metal strips.
  • the magnetic field in the magnetic heat treatment is applied in the direction to be the short side of the magnetic core for antenna, in other words, the width direction, or the thickness direction. Application of the magnetic field in this direction increases the antenna properties Q.
  • the thin metal strips are stacked through an insulating layer made of a material such as a polyimide resin.
  • a method for manufacturing the laminate may include heat press bonding.
  • the roll press method is preferable since continuous stacking can be attained.
  • the magnetic core for antenna is cut out of the laminate only along the width direction of the thin metal strip. Machining of the stacking side surface on the long side will extremely reduce the antenna properties Q of the laminate. As the reason therefor, it is presumed that when the machined surface of the stacking surface becomes larger, machining strain remains and orientation of the given induced magnetic anisotropy becomes uneven, and cutting chippages of the thin metal strip and the resin generated by machining enter between the thin metal strips so that the thin metal strips are conducted and eddy current loss easily increases.
  • Heat treatment of the thin metal strip in the magnetic field can induce magnetic anisotropy in the thin metal strip.
  • induced magnetic anisotropy is preferably given perpendicular to a magnetic flux generating direction (in the width direction or thickness direction of the thin metal strip).
  • an endmost part on the short side of the continuous thin metal strips or laminate is preferably cut off. Magnetic anisotropy is not sufficiently given at the endmost part on the short side due to an effect of a demagnetizing field. If the magnetic core for antenna includes the endmost part, the antenna properties decrease. A region to be cut is preferably not less than 1 mm from the endmost part, and more preferably not less than 2 mm.
  • the end part influenced by the demagnetizing field must be included in the magnetic core for antenna as it is.
  • the elongated laminate is heat treated in the magnetic field, and then cut along the width direction thereof so as to have a desired length.
  • the present method is applied to the magnetic core for antenna having a width of not more than 5 mm.
  • the demagnetizing field becomes larger as the width is smaller.
  • the present production method is particularly preferable for producing an antenna having a width of not more than 5 mm which is difficult to give magnetic anisotropy, since the magnetic heat treatment is performed on the thin metal strip or laminate which do not have the end yet formed and then the thin metal strip or laminate is processed.
  • thermosetting resin or the like When the width exceeds 5 mm and a thermosetting resin or the like is used as an adhesive, stacked layers easily peel off. This is because a gas is generated from the resin when heat is applied thereto during drying process, or the magnetic heat treatment, etc., and an adhesion surface of the stacked layers becomes smaller due to the gas. When the width is not more than 5 mm, such a problem of peeling off reduces since the generated gas escapes from the side surface of the laminate.
  • the thin metal strip is not more than 30 ⁇ m in thickness.
  • the Q value remarkably lowers and sensitivity as an antenna deteriorates, and a level of an output signal lowers, and so on.
  • the thin metal strip becomes less practical.
  • the thickness of not more than 20 ⁇ m is more preferable, and the thickness of not more than 18 ⁇ m is still more preferable.
  • the thin metal strips can be electrically insulated by the resin while they are bonded with a resin.
  • a resin polyimide, polyamide imide, epoxy, and the like can be used. From the viewpoint of productivity, it is preferable to apply a liquid resin.
  • a method for giving induced magnetic anisotropy for example, heat treatment is performed at a temperature of not more than the Curie temperature while applying a magnetic field.
  • a method for performing heat treatment in the magnetic field at a comparatively low temperature of not more than 300°C and not more than the Curie temperature of the material is preferable since embrittlement of the material is reduced and properties thereof are rather improved.
  • a relative initial magnetic permeability of the material is not so high, more effect in improvement of the Q value at 100 kHz to 150 kHz is obtained.
  • the relative initial magnetic permeability of the material may be selected depending on an application in which the material is used.
  • the thin metal strip is a (Fe, Co) SiB-based amorphous strip.
  • a CoSiB-based amorphous strip is particularly preferable.
  • a FeSiB-based amorphous strip is also preferable because of its enhanced strength.
  • a nano crystal thin metal strip such as FeSiCuB
  • a thin metal strip is heat treated at a temperature of not less than a eutectic temperature, therefore causing embrittlement of the alloy strip.
  • an amount “b” of Si is in a range of 1 ⁇ b ⁇ 18, and an amount “c” of B is in a range of 5 ⁇ c ⁇ 15.
  • the antenna used for RFID and the like is used at 30 to 200 kHz, and the antenna property Q value useful for the RFID application is obtained when the amount "b" of Si and the amount "c" of B are respectively within the above ranges.
  • the processes includes subsequently, roll quenching, slit processing, applying and drying of a resin, stacking, pressure bonding, and annealing heat treatment.
  • the thin metal band is produced by injecting molten alloy heated at a temperature of not less than the melting point (approximately 1000°C to 1500°C in the case of a usual Fe-based material and Co-based material) on a rotating metal cooling roll from a nozzle having a slit (the single rolling method).
  • the width of the nozzle slit for injection preferably approximately (a thickness of the strip to be produced) is * 0.3 to 0.8 mm. Ceramics such as quartz, silicon nitride and BN are used as a material of the nozzle.
  • the thin metal band may be produced using multiple slits. In the single rolling method, a gap between the cooling roll and the nozzle tip is not less than 20 ⁇ m but not more than 500 ⁇ m when the molten alloy is being injected, and is usually not more than 250 ⁇ m.
  • the thin metal band is peeled off from the cooling roll at a position of 100 to 1000 mm distant from a position of the roll outer circumference directly under the nozzle slit, measured along a roll outer circumference.
  • breakage hardly occurs and a continuous thin metal band having a length not less than 200 m in the longitudinal direction can be produced.
  • a surface temperature of the cooling roll at a temperature of not more than 100 to 250°C, a long thin metal band can be produced with less embrittlement and smaller curvature of the strip in the width direction.
  • a metal cooling roll is often water-cooled at a time of mass production.
  • Cu and Cu alloys such as Cu-Be, Cu-Zr, and Cu-Cr have great cooling performance and are preferable when producing a wider band.
  • an amount of water for cooling the roll is 0.1 to 10 m 3 /min, a thin metal band having little curvature, breakage, embrittlement, or the like can be produced even when an amount of production is as large as not less than 5 kg.
  • a preferable amount of water is 0.1 to 1 m 3 /min.
  • a diameter of the cooling roll is usually approximately 300 to 1200 mm, and preferably approximately 400 to 1000 mm. Particularly desirably, the diameter thereof is 500 to 800 mm.
  • a thin metal band with satisfactory surface properties can be produced.
  • the thin metal band may be produced in inert gas such as He and Ar, if necessary.
  • the surface properties of the thin metal band is further improved.
  • heated inert gas or nitrogen gas is flown near the nozzle during manufacturing, the surface properties of the thin metal band are also improved.
  • slit processing is performed on the thin metal band thus obtained.
  • the thin metal band 1 set on an uncoiler is withdrawn, and passed through a one pair slitter provided with a plurality of rotary knives on each of top and bottom slitter. Then, the thin metal band is cut to a size of the magnetic core for antenna to obtain a thin strip 1'. The cut thin strip is taken up on a recoiler.
  • a resin solution applied on a thin strip preferably has a thermosetting property.
  • Commercially available resins can be used. Usually, the resin is diluted to 5 to 20% by weight with a solvent for use. When a thickness after drying of the solvent is smaller, a space factor improves. However, a rate of occurrence of defects such as pinholes also increases, and insulation between adjacent strips in the laminate may be insufficient. Accordingly, 0.5 to 3 ⁇ m is preferable as the thickness after drying.
  • a dip method, a doctor blade method, a gravure roll method or the like can be used as the coating method.
  • the gravure roll method is excellent, in terms of homogeneity of a coating thickness and productivity per time (coating speed). In order to apply the resin on both sides using the gravure roll method, it is necessary to apply the resin on one side at one time.
  • a far-infrared heater may be also used for drying.
  • a plurality of slit thin strips are withdrawn from the roll, and are continuously stacked with a hot roll.
  • the thin strips may be cut to a certain length, stacked, and placed into a mold, and then heat-pressed.
  • a movable mold for applying pressure contacts the top and bottom strips in the laminate, a commercially available resin film may be sandwiched between the laminate and the movable mold so that the laminate can released from the mold after the pressure bonding in the subsequent step.
  • the laminate is heated preferably in a nitrogen atmosphere.
  • a temperature in a furnace is increased to a glass transition point of the coated resin. With holding the temperature, pressure is applied on the thin metal strips to bond them to each other.
  • An upper limit of the temperature is less than the thermal decomposition starting temperature of the resin.
  • the applied pressure is not less than 1 MPa since the resin solution sufficiently matches the adjacent resin film or the thin metal strip surface.
  • the pressure exceeds 70 MPa, adjacent thin metal strips may contact each other.
  • the applied pressure is not always necessary, and the laminate can be produced only by stacking.
  • Anisotropy can be induced in the laminate by heat treating the laminate at a temperature of not more than the Curie temperature while applying a magnetic field to the laminate in the width direction thereof.
  • the process to give anisotropy may be performed in a state of the thin metal band or in a state of the thin strip.
  • a magnetic field of not less than 200 A/m may be applied, preferably not less than 400 A/m. Any of a direct current magnetic field, an alternating current magnetic field, or a repeated pulsed magnetic field may be used as the magnetic field to be applied.
  • the magnetic field may be applied only in a part of a heat treatment pattern.
  • the Fe-based amorphous metal strip having the above-mentioned composition is heat treated at 300 to 400°C, and the Co-based amorphous metal strip is heat treated at 300 to 600°C. Since the material embrittles at this time, defects such as chips and cracks may occur if pressure is applied on the amorphous metal strip laminate during annealing heat treatment.
  • annealing is performed preferable without applying load.
  • the same atmosphere as that in the pressure bonding process is preferable.
  • Heat treatment time of 0.1 to 20 hours is preferable.
  • An atmosphere in a heat treating furnace may be inert gas such as argon or nitrogen gas, in a vacuum or in air depending on the case.
  • temperature distribution of the magnetic core during heat treatment is controlled within 10°C.
  • An average heating rate is preferably 0.3 to 100°C/min for not less than 0.5 hours, and an average cooling rate is preferably 0.3 to 300°C/min. The heating rate of 1 to 20°C/min, a maximum temperature of 300 to 370°C for 1 to 3 hours are further preferable.
  • the same effect is also obtained by two-stage heat treatment, by heat treatment for a long time at low temperature of not more than 250°C, or the like. Even in the case of low-temperature heat treatment, the range of 320 to 350°C is preferably set in a part of a heat treatment pattern for approximately 0.2 to 1 hour.
  • a heat treatment pattern is preferable such that the magnetic core is first maintained at a temperature lower than a target temperature, then heated and maintained at the target temperature and cooled at the cooling rate of 0.3 to 5°C/min.
  • heat treatment is usually performed in an inert gas atmosphere at a dew point of not more than -30°C.
  • heat treatment is performed in an inert gas atmosphere whose dew point is not higher than -60°C, fluctuation is further reduced.
  • the present invention it is possible to provide a magnetic core for antenna having a high Q value (namely, antenna properties) and a high-performance antenna using the magnetic core for antenna with a simple production method.
  • Fig. 1 shows a laminate 3 obtained by heat treating a thin metal strip 1 in a magnetic field, and stacking the thin metal strips 1 through an insulating layer 2.
  • a longitudinal (traverse) direction in Fig. 1 is a longitudinal direction of a thin strip obtained by slitting the thin metal band produced with a hyperquenching roll.
  • a magnetic field is applied in a direction perpendicularly to the longitudinal direction, and reference numeral 4 denotes a direction of induced magnetic anisotropy.
  • the thin metal strip 1 is coated with a polyamic acid solution, which is a precursor of a polyimide resin, and pressure bonded by roll pressing.
  • the stacking process can be performed in a roll to roll (Roll-to-Roll) process, and thus continuous manufacturing is possible.
  • the laminate is cut along a cutout line 5 only along a width direction (short side direction) so that the cut laminate may have a long side in the longitudinal direction thereof.
  • Order of the stacking process and annealing heat treatment process can be changed depending on a temperature of each process, and continuous processing is possible. For that reason, the manufacturing method is flexible and also has the advantage of reduction of manufacturing cost.
  • Figs. 3A and 3B are diagrams showing a process for producing a magnetic core for antenna in the prior art.
  • the thin metal band 1 is cut along a cutout line 15 in a direction perpendicularly to a direction 14 of induced magnetic anisotropy applied in the longitudinal direction, and a plurality of metal thin pieces 6 are obtained. Subsequently, the plurality of metal thin pieces 6 are stacked through a resin layer, and a magnetic core 7 for an antenna is obtained.
  • Fig. 3B the thin metal bands 1 are stacked through a resin layer, and a laminate 3' to which induced magnetic anisotropy is given in the longitudinal direction is obtained.
  • the laminate 3' is cut along the cutout line 15 in the direction perpendicularly to the direction 14 of induced magnetic anisotropy, and a magnetic core 7 for an antenna is obtained.
  • strain is induced in the strip by cutting, so that magnetic properties deteriorate.
  • the antenna property Q value improves if the laminate 3 is immersed in an etching solution to remove the scraps after cut, or if a process for removing a cutting surface containing strain is employed.
  • the etching process causes increase of cost, and further, reliability may deteriorate due to the residual etching solution.
  • the thin metal strips are stacked, and subsequently the laminate is cut only along the width direction which is to be the short side of the magnetic core for antenna after stacking, in order to suppress the influences. This suppresses the above-mentioned influences as much as possible.
  • a strip roll By winding the thin strip in a rolled form, a strip roll was produced. Then, as shown in Fig. 2B , a laminate was produced by simultaneously withdrawing the thin strips from a plurality of strip rolls. While the thin strips were withdrawn, a polyamic acid solution that is a precursor of a thermosetting polyimide resin was applied in 10 -3 kg/m 2 (not shown). A total of 23 sheets of thin strips coated with the resin were heated at 360°C by roll pressing 10 having a feed-speed of 300 mm/min to produce a long laminate having a width of 2 mm and 23 layers.
  • the long laminate after roll pressing was subjected to annealing in order to cure the polyimide resin and remove distortion in the strips generated during the roll pressing. Moreover, in order to induce magnetic anisotropy in the strip, the long laminate was passed through a magnetic field generator 8, and a magnetic field of 320 kA/m was applied to the strip in the width direction thereof. Then, the long laminate was temporarily cut by a cutting device 9 to have a length of 1 m.
  • the long laminate was cut with a revolving diamond cutter along the width direction of the strip to produce a magnetic core for antenna having a width of 2 mm, a length of 18 mm, and 23 stacked layers.
  • a cutting trace caused by the diamond cutter was observed on a stacking surface in a width direction of the magnetic core for antenna. While the displacement of the strips on the stacking surface in a longitudinal direction was not less than 0.5 ⁇ m, that in the width direction (short side direction) was not less than 0.5 ⁇ m.
  • Comparative Example 1 is a sample in a case where production was made in the same manner as Example 1 except that no magnetic field was applied.
  • Comparative Example 2 is a sample in a case where the thin metal band was subjected to slit processing to have a dimension (18 mm) in the longitudinal direction of the magnetic core for antenna, and then the thin metal strips were stacked, and the obtained laminate was cut in the longitudinal direction so as to have a width of 2 mm.
  • Comparative Example 3 is a sample in a case where the thin metal strips were stacked to produce a laminate, and then the obtained laminate was cut both in the longitudinal direction and in the width direction (short side direction) to produce a magnetic core for antenna.
  • Comparative Example 4 is a sample in a case where the laminate was cut in the longitudinal direction and then etched.
  • Table 1 shows that the example 1 without etching according to the present invention can obtain the Q value as comparable with that of Comparative Example 4 (etching is essential).
  • Q value Example 1 54 Comparative Example 1 (without applying a magnetic field) 40 Comparative Example 2 (cut in the longitudinal direction) 45 Comparative Example 3 (cut in the longitudinal and width directions) 44 Comparative Example 4 (cutting in the longitudinal direction and etching) 55
  • An antenna was produced using the magnetic core for antenna of Example 1.
  • An enamel-coated copper wire having a diameter of 0.07 mm and insulated was wound around the magnetic core for antenna for 1200 turns.
  • a magnetic field having a frequency of 40 kHz and a magnetic field strength of 14 pT was applied to the antenna from the outside as an effective value of an alternating current magnetic field corresponding to a magnetic field component of an electromagnetic wave. Then, an output voltage was measured.
  • Table 2 shows results. Table 2 shows that an output voltage comparable with that of Comparative Example 4 is obtained.
  • the amorphous magnetic alloy band was subjected to slit processing in a longitudinal direction of the strip, and a thin strip having a width of 2 mm was obtained.
  • the thin strip was continuously passed through a heat treating furnace, and simultaneously, a magnetic field of 320 kA/m was applied to the thin strip in the width direction thereof.
  • a polyamic acid solution that is a precursor of a thermosetting polyimide resin, was applied, in 10 -3 kg/m 2 , to the thus-obtained thin strip having magnetic anisotropy. Then, 23 sheets of the thin strips coated with the resin were prepared. Subsequently, the 23 sheets of thin strips were heated at 360°C by roll pressing having a feed-speed of 300 mm/min to produce a long laminate having a width of 2 mm and 23 layers.
  • the long laminate was cut by a revolving diamond cutter along the width direction thereof to produce a magnetic core for antenna having a width of 2 mm, a length of 18 mm, and 23 stacked layers.
  • An amorphous magnetic alloy band represented by Co ba1 .Fe 1.3 Mn 3.7 Mo 2.5 Si 14.6 B 9.5 (atomic %) and having a width of 20 mm and a thickness of 15 ⁇ m was produced continuously.
  • This amorphous magnetic alloy strip was continuously passed through a heat treating furnace, and simultaneously, a magnetic field of 320 kA/m was applied to the amorphous magnetic alloy strip in the thickness direction thereof.
  • amorphous magnetic alloy band having magnetic anisotropy was subjected to slit processing in the longitudinal direction thereof, and a thin strip having a width of 2 mm was obtained.
  • a polyamic acid solution that is a precursor of a thermosetting polyimide resin was applied in 10 -3 kg/m 2 , to the thin strip. Then, 23 sheets of the thin strips coated with the resin were prepared. Subsequently, the 23 sheets of thin strips were heated at 360°C by roll pressing having a feed-speed of 300 mm/min to produce a long laminate having a width of 2 mm and 23 layers.
  • the long laminate was cut by a revolving diamond cutter in the width direction thereof to produce a magnetic core for antenna having a width of 2 mm, a length of 18 mm, and 23 stacked layers.
  • the amorphous magnetic alloy strips each having a width of 3 mm, 4.5 mm, 6 mm and 10 mm were prepared. Under the same conditions as those in Example 1 except for the width, 250 of the magnetic cores for an antenna were produced for each width mentioned above. Out of the magnetic cores for an antenna, defective items in which peeling off occurred between stacked layers of the strips of the magnetic core for antenna were discriminated by inspection, and yield rate was examined. Table 3 shows the result. When the width of the strip exceeds 5 mm, the yield rate suddenly deteriorates. As for a cause of such peeling off, it is presumed that the thermosetting polyimide resin used as the adhesive layer generates gas when drying or heating during heat treatment in a magnetic field, and the gas did not escape from the side surface of the laminate. [Table 3] Width of alloy strip (mm) Yield 1.0 100.0 2.0 100.0 3.0 98.0 4.0 95.2 4.5 92.8 6.0 82.4 10.0 74.4
  • the antenna according to the present invention can be used for a radio wave receiving antenna used for radio-controlled clocks, and keyless entry systems for automobiles, residences etc., and a RFID tag system. Particularly, since the antenna according to the present invention can be miniaturized, the antenna according to the present invention has possibility of launching a new ubiquitous era.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Soft Magnetic Materials (AREA)

Claims (4)

  1. Verfahren zum Herstellen eines Magnetkerns (7) für eine Antenne, wobei dünne Metallstreifen (1') mit einer Dicke von 5-100 µm aufgestapelt werden, umfassend die folgenden Schritte:
    Verarbeiten eines dünnen Metallbandes (1) mit einer Dicke von 5-100 µm in dünne Streifen (1') mit einer Dicke des gewünschten Magnetkerns (7);
    Aufstapeln der dünnen Streifen (1') durch eine Harzschicht (2), um ein Laminat (3) zu bilden;
    Versehen des Laminats (3) mit magnetischer Anisotropie entlang einer Breitenrichtung (4) des Laminats (3) und dann
    Schneiden des Laminats (3) entlang dessen Breitenrichtung (4), damit es eine Länge des erwünschten Magnetkerns (7) erhält.
  2. Verfahren nach Anspruch 1, gekennzeichnet dadurch, dass der Verarbeitungsschritt das Schneiden umfasst.
  3. Verfahren nach einem der vorhergehenden Ansprüche, gekennzeichnet dadurch, dass der Verarbeitungsschritt das Verarbeiten des dünnen Metallbandes (1) in dünne Streifen (1') so umfasst, dass sie eine Breite von nicht mehr als 5 mm aufweisen.
  4. Verfahren nach einem der vorhergehenden Ansprüche, gekennzeichnet dadurch, dass die Harzschicht (2) Polyamidsäurelösung umfasst, die eine Vorstufe eines thermohärtenden Polyimid-Harzes ist.
EP08740203.8A 2007-04-13 2008-04-10 Magnetkern für eine antenne, verfahren zur herstellung eines magnetkerns für eine antenne und antenne Active EP2139011B1 (de)

Applications Claiming Priority (2)

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JP2007106356 2007-04-13
PCT/JP2008/057102 WO2008133026A1 (ja) 2007-04-13 2008-04-10 アンテナ用磁心、アンテナ用磁心の製造方法、およびアンテナ

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CN101657868A (zh) 2010-02-24
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EP2139011A4 (de) 2013-09-04
JP4471037B2 (ja) 2010-06-02
EP2139011A1 (de) 2009-12-30

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