JP4574155B2 - Magnetic core and its use - Google Patents

Description

  The present invention relates to a magnetic laminate in which magnetic metal ribbons and resin layers are alternately laminated, and at least the magnetic metal ribbon is laminated with respect to one of the magnetic flux generation directions of the magnetic laminate. The present invention relates to a magnetic laminate that is laminated in a state where the end face positions are shifted, a magnetic laminate that is obtained by laminating a plurality of the magnetic laminates, a magnetic core that uses these, an antenna, and a method for manufacturing the magnetic laminate.

  In recent years, many electrical parts, electronic parts and products that use magnetic materials have been required to have higher magnetic performance (high magnetic permeability), smaller size, and thinner thickness. Loss, high magnetic permeability, high magnetic flux density), and being small and thin.

  In response to such market demand, when a magnetic metal material having high magnetic properties such as amorphous metal is conventionally used as a bulk body, a thin film of this magnetic metal material is laminated to form a magnetic laminate. Forming has been done. Specifically, an amorphous metal ribbon having a thickness of about 15 to 50 μm is used as a ribbon of magnetic metal material, and a specific adhesive is uniformly applied to the surface of the amorphous metal ribbon and laminated. Thus, a magnetic laminate is often formed. For example, Patent Document 1 discloses a magnetic laminate in which amorphous metal ribbons coated with an adhesive mainly composed of a high heat-resistant polymer compound are stacked, pressure-bonded with a rolling roll, and heat bonded. The manufacturing method is described.

  More specifically, for example, as shown in FIG. 1-1, a magnetic base material 16 in which a resin layer 15 such as an adhesive is formed on one surface of a strip-shaped magnetic metal thin strip 13 is replaced with a magnetic metal thin strip. 13 and the resin layer 15 are laminated so as to be alternately repeated and pressure-bonded or the like, thereby forming the rectangular magnetic laminate 11.

  However, when such a rectangular magnetic layered body is used as a magnetic core and a coil is provided by winding a coated conductor around the magnetic core, the magnetic layered body is counteracted by demagnetizing fields generated at both ends with respect to the magnetic flux generation direction. Since the number of turns of the coil is set in consideration of the magnetic field, it has been difficult to meet both the demands of reducing the number of turns of the coil, reducing the size and thickness, and improving the magnetic performance.

  On the other hand, conventionally, as shown in FIG. 1-2, a magnetic base material in which a resin layer 15 is formed on one surface of a magnetic metal ribbon 13 is punched with a parallelogram (excluding rectangular and square) molds. By stacking the punched magnetic base material 18 so that the magnetic metal ribbon 13 and the resin layer 15 are alternately repeated, both end portions with respect to the magnetic flux generation direction are slanted (however, the stacked end faces of both end portions are A magnetic laminate 17 is proposed which is a plane that is perpendicular to the bottom of the laminate. This magnetic laminate 17 is known to have an effect of reducing the demagnetizing factor as compared with the magnetic laminate 11 of FIG. 1-1.

However, in the magnetic laminated body 17 of FIG. 1-2, when it is going to form a coil by winding a conducting wire in the direction parallel to the z-axis direction of the magnetic laminated body 17, compared with the magnetic laminated body 11 of FIG. As a result, the winding width is shortened, which causes thickening of the winding, and there is a problem that it is contrary to the demand for a reduction in size and thickness.

In addition, in order to avoid this thickening, when a conductor is wound in a direction parallel to the y-axis direction of the magnetic laminate 17 to form a coil, the conductor is wound obliquely around the laminate 17. Since the winding length of one turn becomes long, the resistance of the winding becomes large, and is obtained as Q factor (Quality factor; Q = ωL / R. Ω = 2πf, f is frequency, L is inductance, R is coil This represents a problem that the resistance including the loss of (2) is small, which is contrary to the demand for high magnetic performance.

As a result of intensive investigations in view of such circumstances, the present inventors have found that the above-mentioned problems can be solved by a magnetic laminated body having a specific shape on the laminated end surface with respect to the direction of magnetic flux generation, thereby completing the present invention. It came to.
JP 58-175654 A

  It is an object of the present invention to provide a magnetic laminate, a method for producing the magnetic laminate, and a magnetic core and an antenna using the magnetic laminate that satisfy both the demands for high magnetic performance and reduction in size and thickness.

  The magnetic laminate according to the present invention is a magnetic laminate in which magnetic metal ribbons and resin layers are alternately repeated, and at least the magnetic metal ribbon is in the direction of magnetic flux generation of the magnetic laminate. It is characterized by being laminated in a state in which the position of the laminated end face is shifted with respect to one. Here, the lamination | stacking end surface of a magnetic metal ribbon means the surface of the thickness direction of a magnetic metal ribbon.

  In the magnetic laminate, a magnetic base material in which a resin layer is formed on at least a part of one side or both sides of a magnetic metal ribbon has a laminated end face position shifted with respect to one of the magnetic flux generation directions of the magnetic laminate. It is preferable that they are laminated in a state of being. Here, the lamination end surface of the magnetic base material means a surface formed by laminating the surface in the thickness direction of the magnetic metal ribbon and the surface in the thickness direction of the resin layer.

  Furthermore, it is preferable that the magnetic layered body is formed by cutting so that the end surface of the magnetic layered body with respect to the magnetic flux generation direction forms one inclined surface when viewed from the bottom of the layered body. Here, the lamination end surface of the magnetic laminate means a surface formed by laminating a plurality of magnetic metal ribbons in a thickness direction and a plurality of resin layers in a thickness direction.

  Another magnetic laminate according to the present invention is characterized in that a plurality of the magnetic laminates are laminated such that magnetic metal ribbons and resin layers are alternately repeated.

  The magnetic core according to the present invention is characterized by using any one of the magnetic laminates.

  The antenna according to the present invention is characterized by using the magnetic core.

  In the method for producing a magnetic laminate according to the present invention, a magnetic base material in which a resin layer is formed on at least a part of one side or both sides of a magnetic metal ribbon is alternately repeated with the magnetic metal ribbon and the resin layer. Thus, when laminating | stacking, it is characterized by laminating | stacking the said magnetic base material, shifting the lamination | stacking end surface position with respect to one of the magnetic flux generation directions of a magnetic laminated body.

  In another method for producing a magnetic laminate according to the present invention, a magnetic base material having a resin layer formed on at least a part of one side or both sides of a magnetic metal ribbon, the magnetic metal ribbon and the resin layer are The magnetic layered body is laminated so as to be alternately repeated, and the laminated end surface with respect to the magnetic flux generation direction of the magnetic laminated body is cut so as to form one slope as seen from the bottom of the laminated body.

  According to the magnetic laminate of the present invention, since the demagnetizing factor can be effectively reduced and the inductance can be improved, the use of these has high magnetic characteristics and greatly increases the number of windings of the coil. A reduced small or thin electrical component or electronic component can be provided.

  According to the magnetic core and antenna of the present invention, the magnetic characteristics can be improved, and even if the number of windings of the coil is greatly reduced, the magnetic characteristics equivalent to or higher than the conventional one can be maintained. These can be reduced in size and thickness.

  Further, according to the method for manufacturing a magnetic laminate of the present invention, the magnetic laminate has a specific shape on the end face with respect to the direction of magnetic flux generation, and satisfies the requirements of both high magnetic performance and miniaturization / thinning. The body can be provided.

  Hereinafter, the present invention will be specifically described.

((Magnetic metal ribbon))
The magnetic metal ribbon used in the present invention is made of a magnetic metal material. As the magnetic metal material, a high permeability material is used, and even an amorphous magnetic metal material is a nanocrystalline magnetic metal material. Can also be used.

  Of these, Fe-based and Co-based amorphous metal materials are preferably used as the amorphous magnetic metal material. Magnetic metal ribbons made of these amorphous metal materials are usually obtained by quenching molten metal using a quenching roll.

Examples of the amorphous magnetic metallic material, the general formula _{(Fe 1-x M x)} 100-abc Si a B b M 'c ( wherein, M is Co and / or Ni, M' is Nb, Mo, Zr , W, Ta, Hf, Ti, V, C
It represents one or more elements selected from r, Mn, Y, Pd, Ru, Ga, Ge, C, and P. x is an atomic ratio, a, b, and c are atomic%, and 0 ≦ x <1, 0 ≦ a ≦ 24, 4 ≦ b ≦ 30, and 0 ≦ c ≦ 10, respectively) Can do. In particular, in applications where high magnetic permeability is required, it is preferable to use an amorphous metal material containing Co as a main component. In applications such as magnetic shielding that shield high-density magnetic flux, it is preferable to use an amorphous metal material mainly composed of Fe having a high saturation magnetic flux density.

Examples of the Fe-based amorphous metal material used in the present invention include Fe-semimetal-based amorphous metal materials such as Fe-B-Si-based, Fe-B-based, and Fe-PC-based, and Fe-Zr-based materials. And Fe-transition metal-based amorphous metal materials such as Fe-Hf and Fe-Ti. For example, in the Fe-Si-B system, Fe ₇₈ Si ₉ B ₁₃ (at%), Fe ₇₈ Si ₁₀ B ₁₂ (at%), Fe ₈₁ Si _13.5 B _13.5 (at%), Fe ₈₁ Si _13.5 B _13.5 C ₂ (at%), Fe ₇₇ Si ₅ B ₁₆ C
r ₂ (at%), Fe ₆₆ Co ₁₈ Si ₁ B ₁₅ (at%), Fe ₇₄ Ni ₄ Si ₂ B ₁₇ Mo ₃ (at
%). Of these, Fe ₇₈ Si ₉ B ₁₃ (at%) and Fe ₇₇ Si ₅ B ₁₆ Cr ₂ (at%) are preferably used. In particular, it is preferable to use Fe ₇₈ Si ₉ B ₁₃ (at%). Examples of the composition system of the Co-based amorphous metal material include a Co—Si—B system and a Co—B system. Among these, the following compositions are more preferable. That is, the general formula (Co _1-c
Fe _c ) _1-ab X _a Y _b (wherein X represents at least one element selected from Si, B, C, Ge, Y represents Zr, Nb, Ti, Hf, Ta, W, It is represented by at least one element selected from Cr, Mo, V, Ni, P, Al, Pt, Rh, Ru, Sn, Sb, Cu, Mn, and a rare earth element, where c, a, and b are respectively , 0 ≦ c ≦ 0.2, 10 <a ≦ 3
5, 0 ≦ b ≦ 30, where a and b are atomic%). The substitution of Co by Fe in the amorphous metal material tends to contribute to an increase in saturation magnetization of the amorphous alloy. For this reason, the substitution amount c is preferably 0 ≦ c ≦ 0.2. Furthermore, it is preferable that 0 ≦ c ≦ 0.1. The element X is an element effective in reducing the crystallization speed for making amorphous when the amorphous metal material is produced. If the element X is 10 atomic% or less, amorphization is reduced and a part of crystalline is mixed, and if it exceeds 35 atomic%, an amorphous structure is obtained, but the mechanical properties of the alloy ribbon are obtained. The strength decreases, and a continuous ribbon cannot be obtained. Therefore, the amount a of the X element is preferably 10 <a ≦ 35, and more preferably 12 ≦ a ≦ 30. The Y element is effective in the corrosion resistance of the magnetic metal ribbon used in the present invention. Among these, particularly effective elements are Zr, Nb, Mn, W, Mo, Cr, V, Ni, P, Al, Pt, Rh, and Ru. If the amount of Y element added exceeds 30 atomic%, there is an effect of corrosion resistance, but the mechanical strength of the ribbon becomes weak, so 0 ≦ b ≦ 30 is preferable. A more preferable range is 0 ≦ b ≦ 20.

  Examples of the nanocrystalline magnetic metal material include those obtained by heat-treating a nanocrystalline metal material having the following composition.

(1) General formula (Fe _1-x M _x ) _100-abcd Si _a Al _b B _c M ′ _d
(Wherein M is Co and / or Ni, M ′ is Nb, Mo, Zr, W, Ta, Hf, Ti, V
, Cr, Mn, Pd, Ru, Ge, C, P, one or more elements selected from rare earth elements. x represents an atomic ratio, a, b, c, and d represent atomic%, and 0 ≦ x ≦ 0.5, 0 ≦ a ≦ 24, 0.1 <b ≦ 20, 4 ≦ c ≦ 30, 0 ≦ d ≦ 20)).
(2) General formula (Fe _1-x M _x ) _100-abcd Cu _a Si _b B _c M ′ _d
(In the formula, M is selected from Co and / or Ni, and M ′ is selected from Nb, Mo, Zr, W, Ta, Hf, Ti, V, Cr, Mn, Pd, Ru, Ge, C, P, and rare earth elements. X represents an atomic ratio, a, b, c, and d represent atomic%, and 0 ≦ x ≦ 0.4, 0.1 ≦ a ≦ 3, b ≦ 19, and 5 ≦, respectively. c ≦ 25, 0 <d ≦ 20, 15 ≦ b + c ≦ 30).
(3) General formula (Fe _1-x M _x ) _100-ab B _a M ′ _b
(Wherein M is selected from Co and / or Ni, M ′ is selected from Nb, Mo, Zr, W, Ta, Hf, Ti, V, Cr, Mn, Pd, Ru, Ga, Ge, C, and rare earth elements. X represents an atomic ratio, a and b represent atomic%, and 0 ≦ x ≦ 0.5, 0 <a ≦ 20, and 2 ≦ b ≦ 20, respectively) The composition represented.
(4) General formula (Fe _1-x M _x ) _100-abc P _a M ′ _b Cu _c
(Wherein M is Co and / or Ni, M ′ is Nb, Mo, Zr, W, Ta, Hf, Ti, V, Cr, Mn, Pd, Ru, Ga, Ge, Al, C, and rare earth elements. X represents an atomic ratio, a, b, c, and d represent atomic%, and 0 ≦ x ≦ 0.5, 0 <a ≦ 20, 2 ≦ b ≦ 20, respectively. 0 ≦ c ≦ 3)). (5) 'in _b (wherein, M is Co and / or Ni, M' formula _{(Fe 1-x M x)} 100-ab M a M is Ta, Zr, Hf, Ti, Nb, Mo, W, V, Cr, Mn, Pd, Ru, Ga, Ge, Si, Al, P, Cu, represents one or more elements selected from rare earth elements, and M ′ represents one or more elements selected from C, N, and O. X represents an atomic ratio, a and b represent atomic%, and the composition is represented by 0 ≦ x ≦ 0.5, 2 <a ≦ 30, and 4 ≦ b ≦ 30.

  These nanocrystalline metal materials can be heat-treated by a known method to obtain nanocrystalline magnetic metal materials.

Among these, as the magnetic metal ribbon used for the magnetic core for antenna, it is preferable to use a magnetic metal ribbon made of a Co-based amorphous metal material or a nanocrystalline magnetic metal material.

  Although these magnetic metal ribbons may be used as they are, it is preferable to perform a heat treatment at 200 ° C. or higher in an inert atmosphere or in vacuum in order to improve magnetic properties. The heat treatment temperature is usually in the range of 200 to 700 ° C, and more preferably in the range of 300 to 600 ° C. The magnetic metal ribbon is usually 10 to 50 μm in thickness, preferably 10 to 30 μm.

((resin))
The resin used in the present invention is not particularly limited, and a known polymer compound can be used, but after forming a resin layer on the magnetic metal ribbon, the magnetic properties of the magnetic metal ribbon are improved. When heat treatment at 200 ° C. or higher is performed, it is effective to use a heat resistant resin that satisfies the following conditions.

  Specifically, the heat-resistant resin used in the present invention has (1) a weight loss amount of 1% by weight or less due to thermal decomposition when subjected to a heat history of 2 hours at 350 ° C. in a nitrogen atmosphere. It is preferable to satisfy at least one of the conditions (2) to (5).

That is, (2) The tensile strength after passing through a heat history of 350 ° C. for 2 hours in a nitrogen atmosphere is 30 MPa or more. (3) The glass transition temperature is 120 ° C to 250 ° C. (4) The temperature at which the melt viscosity is 1000 Pa · s or less is 250 ° C. or more and 400 ° C. or less. (5) After the temperature is lowered from 400 ° C. to 120 ° C. at a constant rate of 0.5 ° C./min, the heat of fusion due to the crystalline material in the resin is 10 J / g or less.

  The weight reduction amount of the above condition (1) is the DTA-TG when the heat resistant resin is dried at 120 ° C. for 4 hours as a pretreatment and then kept at 350 ° C. for 2 hours in a nitrogen atmosphere. It can be measured using (differential thermal analysis / thermogravimetric analyzer), and is usually 1% or less, preferably 0.3% or less. It is preferable for the weight loss amount to be less than or equal to the above numerical value because the occurrence of peeling or swelling of the laminate can be suppressed when heat treatment for improving magnetic properties is performed.

The tensile strength test under the condition (2) is performed according to ASTM D-638. After heat-treating the heat resistant resin at 350 ° C. for 2 hours in a nitrogen atmosphere, a predetermined test piece is prepared and then a tensile test is performed (30 ° C.). The tensile strength is usually 30 MPa or more, preferably 50 MPa or more. If the tensile strength is outside this value, it may not be possible to obtain sufficient effects such as good shape stability.

  The glass transition temperature Tg of the heat resistant resin under the condition (3) is obtained from the inflection point of the endothermic peak indicating the glass transition measured by DSC (differential scanning calorimeter). Tg is 120 ° C. or higher and 250 ° C. or lower, preferably 220 ° C. or lower. When Tg is higher than the above range, the magnetic characteristics may be deteriorated.

The melt viscosity of the condition (4) can be measured using a Koka flow tester, and the temperature at which the melt viscosity is 1000 Pa · s or less is 250 ° C. or more, usually 400 ° C. or less, preferably 350 ° C. Below, it is 300 degrees C or less more preferably. When the temperature of the melt viscosity of 1000 Pa · s or less under is in this range, heat press bonding is possible at a low temperature, and excellent adhesion between the magnetic metal thin strip. When the temperature at which the melt viscosity decreases is high, adhesion failure or the like may occur.

The heat of fusion of condition (5) can be measured using a DSC (Differential Scanning Calorimeter). After the temperature of the heat resistant resin is lowered from 400 ° C. to 120 ° C. at a constant rate of 0.5 ° C./min, the resin The heat of fusion due to the crystallized material is 10 J / g or less, preferably 5 J / g or less, more preferably 1
J / g or less. When the heat of fusion is not more than the above value, the adhesion to the magnetic metal ribbon is excellent.

The molecular weight and molecular weight distribution of the heat-resistant resin are not particularly limited, but if the molecular weight is extremely small, the strength of the resin layer and the adhesive strength with the magnetic metal ribbon may be affected. Therefore, it is preferable that the logarithmic viscosity value measured at 35 ° C. is 0.2 dl / g or more after the resin is dissolved in a solvent that can be dissolved at a concentration of 0.5 g / 100 ml.

  Specific resins that satisfy the above conditions include polyimide resins, silicon-containing resins, ketone resins, polyamide resins, liquid crystal polymers, nitrile resins, thioether resins, polyester resins, arylate resins, sulfone resins, Examples thereof include imide resins and amide imide resins. Among these, it is preferable to use a polyimide resin, a sulfone resin, or an amideimide resin.

Furthermore, the heat resistant resin used in the present invention is preferably thermoplastic. This is to ensure good adhesion with the magnetic metal ribbon and to minimize the stress applied to the magnetic metal ribbon. An example of such a heat-resistant thermoplastic resin is a polyimide resin described in WO03 / 060175.
((Magnetic substrate))
The magnetic substrate used in the present invention is one in which a resin layer is formed on at least a part of one side or both sides of a magnetic metal ribbon.

  The magnetic metal ribbon may or may not be subjected to a heat treatment for improving the characteristics as a magnetic material. When a heat-resistant resin is used as the resin, the magnetic metal ribbon is placed on the magnetic metal ribbon. After forming the resin layer, heat treatment for improving the characteristics as a magnetic material can be performed.

  The resin layer may be formed on at least a part of one or both sides of the magnetic metal ribbon, but it is preferably formed uniformly on the entire surface of one or both sides of the magnetic metal ribbon.

  As a method for forming the resin layer, a known method can be used and is not particularly limited. Specifically, for example, a roll coater method, a gravure coater method, an air doctor coater method, a blade coater method, a knife coater Method, rod coater method, kiss coater method, bead coater method, cast coater method, rotary screen method, slot orifice coater method, etc .; dip coating method; bar code method; spray coating method; spin coating method; A resin layer can be obtained by preparing a coating film of a resin varnish on a magnetic metal ribbon by a coating method or the like and drying it. Here, the resin varnish means a liquid in which a resin or a resin precursor is dispersed or dissolved in an organic solvent. The viscosity of the resin varnish is preferably in the range of 0.005 to 200 Pa · s and 0.01 to 50 Pa · s so that the thickness of the resin layer becomes uniform.

  Moreover, as a method of forming the resin layer only on a part of the magnetic metal ribbon, for example, a gravure coater method using a gravure head in which a groove of a coating film pattern is processed can be exemplified.

  The coating amount varies depending on the magnetic metal ribbon used and the type of resin, but is adjusted so that the thickness of the formed resin layer falls within the following range. That is, the thickness of the resin layer formed on at least a part of one surface or both surfaces of the magnetic metal ribbon is preferably in the range of 0.1 μm to 100 μm, more preferably 1 μm to 10 μm, and even more preferably 2 μm to 8 μm.

  In addition to the above method, any method can be used as long as it can form a resin layer having a thickness in the above range on the magnetic metal ribbon, such as a physical vapor deposition method such as a sputtering method or a vapor phase method such as a CVD method. May be used.

((Magnetic laminate))
The magnetic laminated body of the present invention is a magnetic laminated body in which the magnetic metal ribbon and the resin layer are alternately laminated, and at least the position of the laminated metal end face of the magnetic metal ribbon is that of the magnetic laminate. The layers may be stacked in a shifted state with respect to one of the magnetic flux generation directions, and the method of stacking may be regular or irregular. Moreover, the length of each magnetic metal ribbon or magnetic base in the direction of magnetic flux generation may be the same or different.

Examples of preferable magnetic laminates include the following magnetic laminates (I) to (III).

Magnetic laminate (I) in which at least the magnetic metal ribbon, preferably the above-described magnetic base material, is laminated in a state where the position of the lamination end face is shifted with respect to one of the magnetic flux generation directions of the magnetic laminate,
Magnetic laminated body formed by cutting the laminated end face with respect to the magnetic flux generation direction of the magnetic laminated body, preferably the two laminated end faces with respect to the magnetic flux generating direction of the magnetic laminated body so as to form one slope as viewed from the bottom of the laminated body (II),
A magnetic laminate (III) in which a plurality of magnetic laminates (I) or magnetic laminates (II) are laminated such that magnetic metal ribbons and resin layers are alternately repeated.

  In any of the above cases, when a magnetic laminated body is produced, the laminated structure can be freely designed by laminating and bonding by a multilayer coating method, hot pressing, thermal roll, high frequency welding, or the like. .

  In this case, the magnetic metal ribbon may or may not be subjected to a heat treatment for improving the properties as a magnetic material, but a heat-resistant resin as a resin constituting the resin layer of the magnetic substrate. When is used, after the magnetic base material is formed or the magnetic laminated body is formed, heat treatment for improving the characteristics as a magnetic body can be performed.

  Hereinafter, although the preferable aspect of the magnetic laminated body of this invention is demonstrated more concretely based on figures, this invention is not limited to these.

  First, an example of the magnetic laminate (I) will be described with reference to FIG.

  FIG. 2-1 is a perspective view showing an example of the magnetic laminate (I). In FIG. 2A, the magnetic laminate 21 is formed by laminating a plurality of magnetic base materials 16 each having a resin layer 15 formed on one surface of a magnetic metal ribbon 13 and punched into a rectangular strip shape. In the two laminated end faces (the left and right side faces) with respect to the magnetic flux generation direction of the magnetic laminate 21, the position of the laminated end face of the magnetic base material 16 is shifted with respect to one of the magnetic flux generation directions of the magnetic laminate 21. Are formed by being laminated.

  Next, another example of the magnetic laminate (I) will be described with reference to FIGS. 3-1 and 3-2.

  FIGS. 3A and 3B are cross-sectional views illustrating examples of different magnetic laminates (I).

In FIG. 3A, the magnetic laminate 31 is formed by laminating a plurality of magnetic base materials 16 each having a resin layer 15 formed on one surface of a magnetic metal ribbon 13 and punched into a rectangular strip shape. In this case, the plurality of magnetic base materials 16 include a plurality of magnetic base materials 16 having the same length in the magnetic flux generation direction and different from each other. The two laminated end faces (toward the left end and right end) with respect to the magnetic flux generation direction of the magnetic laminated body 31 are arranged such that each magnetic base material 16 has a laminated end face position periodically with respect to one of the magnetic laminated body 31 in the magnetic flux generating direction. It is formed by laminating in a state shifted to.

  3-2, the magnetic laminate 33 is formed by laminating a plurality of magnetic base materials 16 each having a resin layer 15 formed on one surface of a magnetic metal ribbon 13 and punched into a rectangular strip shape. However, in this case, the plurality of magnetic base materials 16 include a plurality of magnetic base materials 16 whose lengths in the magnetic flux generation direction are the same as or different from each other. The two laminated end faces (toward the left end and the right end) with respect to the magnetic flux generation direction of the magnetic laminated body 33 are shifted in position of the laminated end faces of the magnetic base material 16 with respect to one of the magnetic flux generating directions of the magnetic laminated body 33. However, the way of stacking is not periodic but irregular.

  In the magnetic laminates 21, 31, and 33, the deviation width of the laminated end surfaces of the laminated magnetic base materials 16 with respect to one of the magnetic flux generation directions is appropriately set according to the shape of the magnetic base material 16. Usually, at least the magnetic metal ribbon 13, preferably at least one layer of the magnetic base material 16, is adjacent to the magnetic base material 16 (when there are two adjacent magnetic base materials 16, the one with the larger shift width). In comparison with the length in the direction of magnetic flux generation up to about 1/5. The shift width for each layer can be arbitrarily set, and does not necessarily require that all the layers are shifted from each other as compared to the adjacent layers. When the laminated end faces or the laminated end faces of all the magnetic base materials 16 are combined (that is, each of the two laminated end faces with respect to the magnetic flux generation direction of the magnetic laminated bodies 21, 31, 33) is perpendicular to the laminated body bottom face. What is necessary is just the state which does not form one plane.

In the magnetic laminate 21, the two laminated end faces with respect to the magnetic flux generation direction are stepped slopes having irregularities when viewed from the bottom of the laminate, and in the magnetic laminates 31 and 33, Since each end face is a surface having projections and depressions when viewed from the bottom of the laminate, when a magnetic core or an antenna is manufactured by winding a conductive wire around these magnetic laminates to give a coil, Compared with a rectangular magnetic laminate (for example, FIG. 1-1) in which magnetic base materials are vertically laminated, the demagnetizing factor can be effectively reduced and the inductance can be improved. Therefore, the number of windings of the coil can be greatly reduced, and a small or thin magnetic core or antenna having high magnetic characteristics can be provided. In this case, the coil winding width when winding in parallel in the z-axis direction is the same as that of the magnetic laminate 11 of FIG. Even when wound around, problems such as thickening will not occur.

  Next, an example of the magnetic laminate (II) will be described with reference to FIG.

  FIG. 2-2 is a perspective view showing an example of the magnetic laminate (II). In FIG. 2B, the magnetic laminate 23 is formed by previously laminating a plurality of magnetic base materials each having the resin layer 15 formed on one surface of the magnetic metal thin body 13 to form the magnetic laminate, and then forming the magnetic laminate 23. Are formed by cutting each of two laminated end faces (left and right side faces) with respect to the magnetic flux generation direction so as to form one slope as viewed from the bottom of the laminated body. Here, the lamination | stacking end surface of a magnetic laminated body means the surface formed by laminating | stacking the surface of the thickness direction of several magnetic metal ribbons, and the surface of the thickness direction of a resin layer.

  In this case, the inclination of the laminated end face of the magnetic laminated body 23 as viewed from the bottom of the laminated body can be set as appropriate, but is usually about 85 degrees to 1 degree.

In such a magnetic laminate 23, the two laminated end faces with respect to the direction of magnetic flux formation form slopes that are inclined as seen from the bottom of the laminate, and therefore, a conductive wire is wound around the magnetic laminate to form a coil. When the magnetic core and the antenna are manufactured by applying the magnetic core, the demagnetizing factor can be effectively reduced and the inductance can be improved as compared with a rectangular magnetic laminate as shown in FIG. Therefore, the number of windings of the coil can be greatly reduced, and a small or thin magnetic core or antenna having high magnetic characteristics can be provided. In this case, the magnetic laminate 23 has the same shape as the top surface of FIG. 1-1, and therefore the winding width of the coil when wound in parallel in the z-axis direction is the same. Even when conducting wires are wound so as to have the same number of windings, problems such as thickening of winding do not occur.

  FIG. 2-2 shows a case where the two laminated end faces are parallel to the magnetic flux generation direction of the magnetic laminated body, which is cut and formed so as to form one inclined surface when viewed from the bottom of the laminated body. Alternatively, the two stacked end faces may have different slopes.

  Next, an example of the magnetic laminate (III) will be described with reference to FIGS. 2-3 to 2-5.

FIG. 2-3 is a perspective view showing an example of the magnetic laminate (III). In FIG. 2C, the magnetic layered body 25 has a resin layer 15 formed on one side of the magnetic metal ribbon 13, and the magnetic base material 16 punched into a rectangular strip shape is formed in the direction of magnetic flux generation of the magnetic layered body 25. The magnetic layered body 25 is formed by laminating while shifting the position of the laminated end face with respect to one side. The magnetic layered body 21 of FIG. It can also be said that a plurality of layers are formed so as to be alternately repeated.

In such a magnetic laminated body 25, the two laminated end faces with respect to the magnetic flux generation direction each form a stepped slope having irregularities when viewed from the bottom of the laminated body, so that a conducting wire is provided around the magnetic laminated body. When a magnetic core or an antenna is manufactured by winding a coil, compared with a magnetic laminate (for example, FIG. 1-1) in which strip-like magnetic substrates having the same shape are vertically laminated, The magnetic field coefficient can be further effectively reduced and the inductance can be improved. Therefore, the number of windings of the coil can be greatly reduced, and a small or thin magnetic core or antenna having high magnetic characteristics can be provided. In this case, the coil winding width when winding in parallel in the z-axis direction is the same as that of the magnetic laminate 11 of FIG. Even when wound around, problems such as thickening will not occur.

FIG. 2-4 is a perspective view showing another example of the magnetic laminate (III). In FIG. 2-4, the magnetic layered body 27 has a resin layer 15 formed on one surface of the magnetic metal ribbon 13, and the magnetic base material 18 punched into a parallelogram (excluding rectangle and square) is formed of a magnetic layered body. It is formed by laminating while shifting the position of the laminated end face with respect to one of the magnetic flux generation directions of the body 27.

  In such a magnetic laminated body 27, the two laminated end faces with respect to the magnetic flux generation direction each form a stepped slope having irregularities when viewed from the bottom face of the laminated body in several stages. When a magnetic core or an antenna is manufactured by applying a coil, compared with a magnetic laminate (for example, FIG. 1-2) in which parallel parallel magnetic bases having the same shape are vertically laminated, The demagnetizing factor can be reduced more effectively and the inductance can be further improved. For this reason, the number of windings of the coil can be greatly reduced, and a small or thin magnetic core or antenna having high magnetic characteristics can be provided. In this case, the problem of thickening due to a reduction in winding width when compared with a rectangular magnetic laminate as shown in FIG. .

FIG. 2-5 is a perspective view showing another example of the magnetic laminate (III). 2-5, the magnetic laminate 29 is formed by laminating a plurality of magnetic laminates 23 of FIG. 2-2 such that the magnetic metal ribbon 13 and the resin layer 15 are alternately repeated.

In such a magnetic laminated body 29, the two laminated end faces with respect to the magnetic flux generation direction each form slopes having inclinations when viewed from the bottom of the laminated body, so that a conducting wire is wound around the magnetic laminated body. When a magnetic core or antenna is manufactured by applying a coil, the demagnetizing factor is more effectively reduced and the inductance is further improved as compared with a rectangular magnetic laminate as shown in FIG. Can do. Therefore, the number of windings of the coil can be greatly reduced, and a small or thin magnetic core or antenna having high magnetic characteristics can be provided. In this case, since the magnetic laminate 29 has the same shape as the top surface of FIG. 1-1, the winding width of the coil when winding in parallel in the z-axis direction is the same. Even when conducting wires are wound so as to have the same number of windings, problems such as thickening of winding do not occur.

In addition, the shape of such a magnetic laminated body can be confirmed by observing a magnetic laminated body with an optical microscope, SEM (scanning electron microscope), etc.
((Method for producing magnetic laminate))
The magnetic laminate of the present invention, for example, the above-mentioned magnetic laminate (I) comprises a magnetic base material having a resin layer formed on at least a part of one or both surfaces of a magnetic metal ribbon, and a magnetic metal ribbon and a resin layer. Can be manufactured by laminating the magnetic base material while shifting the position of the laminated end face with respect to one of the magnetic flux generation directions of the magnetic laminated body.

  Specifically, a magnetic base material punched in advance into a predetermined shape is laminated in a mold so as to form a stepped slope when viewed from the bottom of the laminated body, and is manufactured by laminating and bonding by hot pressing or the like can do.

  Alternatively, when a magnetic base material punched into a predetermined shape is laminated in a mold and laminated and bonded by hot press or the like, the mold is slid in a desired direction to apply a sliding stress to the magnetic laminate. After sliding, it can be produced by gluing.

  Another magnetic laminate of the present invention, for example, the above-mentioned magnetic laminate (II), comprises a magnetic base material having a resin layer formed on at least a part of one side or both sides of a magnetic metal ribbon. And the resin layer are alternately and repeatedly laminated, and then the lamination end surface with respect to the magnetic flux generation direction of the magnetic laminate, preferably the two lamination end surfaces with respect to the magnetic flux generation direction of the magnetic laminate, respectively, are viewed from the bottom of the laminate. It can manufacture by cut | disconnecting so that one slope may be formed.

  Specifically, a magnetic base material having a resin layer formed on at least a part of one surface or both surfaces of a magnetic metal ribbon is laminated so that the magnetic metal ribbon and the resin layer are alternately repeated, and hot pressing is performed. After forming a magnetic laminate by laminating and bonding, etc., the end of the magnetic laminate with respect to the direction of magnetic flux generation, preferably both ends can be cut obliquely. You may manufacture by laminating | stacking multiple cut | disconnected magnetic base materials, or laminating | stacking multiple magnetic metal strips and resin layers which cut | disconnected the edge part diagonally, and carrying out lamination | stacking adhesion | attachment by hot press etc. FIG.

  For example, in a laminate in which a strip-shaped magnetic base material in which a resin layer is formed on a magnetic metal ribbon is laminated, for example, an end with respect to the direction of generation of magnetic flux generated in a usage mode such as a magnetic core, preferably Both end portions can be manufactured by cutting each of them obliquely with a rotary blade or a discharge wire cut so as to form one slope as viewed from the bottom of the laminate.

In this case, the heat treatment for improving the magnetic performance of the magnetic metal ribbon may be performed before cutting or after cutting depending on the type of resin used for the resin layer.

Further, another magnetic laminate of the present invention, for example, the magnetic laminate (III) is obtained by laminating a plurality of magnetic laminates (I) or (II) produced as described above in a predetermined mold, and performing hot press It can manufacture by performing the process of.
((Usage))
The magnetic layered product of the present invention can be used as a magnetic core or an antenna by winding a conductive wire around them to provide a coil. When the magnetic laminate of the present invention is used as a magnetic core material, the demagnetizing factor can be effectively reduced and the inductance can be improved. The magnetic core and the antenna can be made smaller or thinner.

FIG. 1-1 is a perspective view illustrating an example of a conventional magnetic laminate. FIG. 1-2 is a perspective view showing another example of a conventional magnetic laminate. FIG. 2-1 is a perspective view showing an example of the magnetic laminate (I) of the present invention. FIG. 2-2 is a perspective view showing an example of the magnetic laminate (II) of the present invention. FIG. 2-3 is a perspective view showing an example of the magnetic laminate (III) of the present invention. FIG. 2-4 is a perspective view showing an example of the magnetic laminate (III) of the present invention. FIG. 2-5 is a perspective view showing an example of the magnetic laminate (III) of the present invention. FIG. 3A is a cross-sectional view showing an example of the magnetic laminate (I) of the present invention. 3-2 is sectional drawing which shows an example of the magnetic laminated body (I) of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 11, 17: Conventional magnetic laminated body 13: Magnetic metal ribbon 15: Resin layer 16, 18: Magnetic base material 21, 23, 25, 27, 29, 31, 33: Magnetic laminated body of this invention

Claims (5)

A magnetic core using a magnetic laminate in which magnetic metal ribbons and resin layers having substantially the same length in the direction of magnetic flux generation are alternately laminated, the magnetic metal ribbon A magnetic core comprising: a magnetic layered body that is laminated in a state where the position of the layered end face is shifted with respect to one of the magnetic flux generation directions of the magnetic layered body. A magnetic base material in which a resin layer is formed on at least a part of one or both surfaces of a magnetic metal ribbon is laminated in a state where the position of the lamination end face is shifted with respect to one of the magnetic flux generation directions of the magnetic laminate. The magnetic core according to claim 1, wherein the magnetic core is a magnetic core. The magnetic core according to claim 1, wherein a laminated end surface of the magnetic laminated body of the magnetic core with respect to a magnetic flux generation direction is cut and formed so as to form one inclined surface when viewed from the bottom of the laminated body . A magnetic core according to any one of claims 1 to 3, wherein a plurality of magnetic laminates of magnetic cores are laminated so that magnetic metal ribbons and resin layers are alternately repeated . An antenna using the magnetic core according to claim 1 .

Images