JP2016108561A - 軟磁性樹脂組成物および軟磁性フィルム - Google Patents
軟磁性樹脂組成物および軟磁性フィルム Download PDFInfo
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Abstract
Description
平均厚みは、例えば、0.1μm以上、好ましくは、0.2μm以上であり、また、例えば、3.0μm以下、好ましくは、2.5μm以下である。軟磁性粒子の扁平率、平均粒子径、平均厚みなどを調整することにより、軟磁性粒子による反磁界の影響を小さくでき、その結果、軟磁性粒子の透磁率(複素透磁率実部μ´)を増加させることができる。なお、軟磁性粒子の大きさを均一にするために、必要に応じて、ふるいなどを使用して分級された軟磁性粒子を用いてもよい。
具体的には、電子比重計(アルファミラージュ製、「MDS−300」)を用いて測定することができる。
軟磁性樹脂組成物に対し軟磁性粒子の体積割合が55.0体積%となるように、固形分換算で、Fe−Si−Al合金88.5質量部、クレゾールノボラック型エポキシ樹脂3.0質量部、フェノールビフェニレン樹脂3.0質量部、アクリル樹脂5.1質量部、熱硬化触媒0.1質量部、分散剤0.1質量部、および、レオロジーコントロール剤0.2質量部を混合することにより、実施例1の軟磁性樹脂組成物を得た。
表1に記載の材料および配合割合にて、実施例2〜3の軟磁性樹脂組成物を得た。各実施例の軟磁性樹脂組成物を用いた以外は、実施例1と同様にして、実施例2〜3の軟磁性フィルム(平均厚み150μm)を製造した。
表1および表2に記載の材料および配合割合にて、実施例4〜6の軟磁性樹脂組成物を得た。各実施例の軟磁性樹脂組成物を用い、熱プレス条件を175℃、30分、20MPaとした以外は、実施例1と同様にして、実施例4〜6の軟磁性フィルム(平均厚み150μm)を製造した。
表1に記載の材料および配合割合にて、比較例1〜2の軟磁性樹脂組成物を得た。各軟磁性樹脂組成物を用いた以外は、実施例1と同様にして、比較例1〜2の軟磁性フィルム(平均厚み150μm)を製造した。
表1および表2に記載の材料および配合割合にて、比較例3〜6の軟磁性樹脂組成物を得た。各比較例の軟磁性樹脂組成物を用い、熱プレス条件を175℃、30分、20MPaとした以外は、実施例1と同様にして、比較例3〜6の軟磁性フィルム(平均厚み150μm)を製造した。
各実施例および各比較例の軟磁性フィルムの実比重(S.G.)を、電子比重計(アルファミラージュ製、「MDS−300」)を用いて測定した。
各実施例および各比較例の軟磁性フィルムの側断面を、SEM(倍率:5000倍)にて、空隙が発生しているか否かを観察した。
各実施例および各比較例の軟磁性フィルムの比透磁率(複素透磁率実部μ´および複素透磁率虚部μ´´)を、インピーダンスアナライザー(Agilent社製、「4291B」)を用いて、1ターン法(周波数1MHz、10MHz)によって測定した。結果を表1および表2に示す。
各実施例および各比較例において、軟磁性樹脂組成物溶液をセパレータ上に塗布し、130℃で2分間乾燥させた後の軟磁性熱硬化性フィルムの表面の外観を観察した。
各実施例の軟磁性樹脂組成物およびそれから得られる軟磁性フィルムは、表1および表2から明らかなように、磁気特性に優れ、空隙の発生を十分に抑制できている。また、成膜性にも優れている。特に、磁気特性のうち複素透磁率実部μ´については、低周波(1MHz)および高周波(10MHz)ともに、各比較例と比べて、数値が高く、より良好な磁束収束を示すことが分かる。複素透磁率虚部μ´´については、低周波(1MHz)および高周波(10MHz)ともに、各比較例と比べて、ほぼ同等の数値であり、磁束損失が低下していないことが分かる。すなわち、磁束損失を防止しつつ、磁束収束を良好にしているため、電子機器が備えるアンテナなどに用いる磁性フィルムとしての特性が優れている。
・低周波向け軟磁性粒子:Fe−Si−Al系合金、扁平状、平均粒子径43μm、平均厚み1μm、比重6.8、磁化容易方向の保磁力3(Oe)未満
・高周波向け軟磁性粒子:Fe−Si−Al系合金、扁平状、磁化容易方向の保磁力3(Oe)以上
・クレゾールノボラック型エポキシ樹脂:上記一般式(1)のエポキシ樹脂、エポキシ当量199g/eq.、ICI粘度(150℃)0.4Pa・s、比重1.21、商品名「KI−3000−4」、東都化成社製
・トリスヒドロキシフェニルメタン型エポキシ樹脂:上記一般式(2)のエポキシ樹脂、エポキシ当量169g/eq.、ICI粘度(150℃)0.1Pa・s、比重1.25、商品名「EPPN−501HY」、日本化薬社製
・ビスフェノールA型エポキシ樹脂:エポキシ当量180g/eq.、ICI粘度(150℃)0.05Pa・s、比重1.15、商品名「エピコートYL980」、三菱化学社製
・フェノールビフェニレン樹脂:上記一般式(4)のフェノール樹脂、水酸基当量203g/eq.、ICI粘度(150℃)0.05Pa・s、比重1.18、商品名「MEH−7851SS」、明和化成社製
・フェノールノボラック樹脂:上記一般式(3)のフェノール樹脂、水酸基当量104g/eq.、ICI粘度(150℃)0.03Pa・s、比重1.2、商品名「レヂトップLVR8210DL」、群栄化学工業社製
・アクリル樹脂:カルボキシ基およびヒドロキシ基変性のアクリル酸エチル−アクリル酸ブチル−アクリロニトリル共重合体、重量平均分子量900,000、比重1.00、商品名「テイサンレジン SG−70L」(樹脂含有割合12.5質量%)、ナガセケムテックス社製
・熱硬化触媒:2−フェニル−1H−イミダゾール4,5−ジメタノール、比重1.33、商品名「キュアゾール2PHZ−PW」、四国化成社製
・分散剤:ポリエーテルリン酸エステル、酸価17、比重1.03、商品名「HIPLAAD ED152」、楠本化成社製
・レオロジーコントロール剤:ウレア変性中極性ポリアマイド、比重0.86、商品名「BYK430」(固形分30質量%)、ビックケミージャパン社製
7 軟磁性粒子
Claims (7)
- 扁平状の軟磁性粒子と、エポキシ樹脂、フェノール樹脂およびアクリル樹脂を含有する樹脂成分とを含有し、
前記エポキシ樹脂が、3つ以上の官能基を有するエポキシ樹脂のみからなり、
前記フェノール樹脂が、3つ以上の官能基を有するフェノール樹脂のみからなり、
前記樹脂成分における前記アクリル樹脂の含有割合が、25質量%以上であることを特徴とする、軟磁性樹脂組成物。 - 前記軟磁性粒子を除く軟磁性粒子除外成分100質量部に対して、前記エポキシ樹脂および前記フェノール樹脂の合計含有量が20質量部以上99質量部以下であることを特徴とする、請求項1に記載の軟磁性樹脂組成物。
- 前記エポキシ樹脂のエポキシ当量が、230g/eq.以下であり、
前記フェノール樹脂の水酸基当量が、230g/eq.以下であることを特徴とする、請求項1または2に記載の軟磁性樹脂組成物。 - 前記3つ以上の官能基を有するエポキシ樹脂が、トリスヒドロキシフェニルメタン型エポキシ樹脂であり、
前記3つ以上の官能基を有するフェノール樹脂が、フェノールノボラック樹脂であることを特徴とする、請求項1〜3のいずれか一項に記載の軟磁性樹脂組成物。 - 前記3つ以上の官能基を有するエポキシ樹脂が、クレゾールノボラック型エポキシ樹脂であり、
前記3つ以上の官能基を有するフェノール樹脂が、フェノールビフェニレン樹脂であることを特徴とする、請求項1〜3のいずれか一項に記載の軟磁性樹脂組成物。 - 前記軟磁性粒子の含有割合が、40体積%以上であることを特徴とする、請求項1〜5のいずれか一項に記載の軟磁性樹脂組成物。
- 請求項1〜6のいずれか一項に記載の軟磁性樹脂組成物を加熱硬化することにより得られることを特徴とする、軟磁性フィルム。
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