TW201709232A - Coil module and method for producing same - Google Patents

Abstract

This coil module, which is a coil module for wireless communication or wireless power transmission using a frequency band of 13.56 MHz or 6.78 MHz, is provided with: a coil substrate that comprises a substrate and a coil pattern that is provided to one side of the substrate in the thickness direction; an adhesive layer that is provided to one side of the coil substrate in the thickness direction and is formed from an adhesive composition that contains thermally conductive particles, soft magnetic particles, and an adhesive resin; and a magnetic layer that is provided to one side of the adhesive layer in the thickness direction and is formed from a magnetic composition that contains soft magnetic particles and a resin.

Description

Coil module and method of manufacturing same

The present invention relates to a coil module and a method of manufacturing the same.

A position detecting device that moves a pen type position indicator on a position detecting plane to detect a position is called a digital converter, and is popularized as an input device of a computer. The position detecting device includes a position detecting plane plate and a circuit board disposed under the circuit and having a loop coil formed on a surface of the substrate. Moreover, the position of the position indicator is detected by applying electromagnetic induction in the frequency band of 500 kHz generated by the position indicator and the loop coil.

In the position detecting device, in order to improve the electromagnetic induction by controlling and converging the magnetic flux generated when the electromagnetic induction is made, and to reduce the magnetic flux that is diverged to the outside, a method of arranging a magnetic layer on the circuit substrate is proposed (for example, refer to Patent Document 1).

Patent Document 1 discloses a magnetic film laminated circuit board including a circuit board, a surface layer, and a magnetic layer containing soft magnetic particles in this order.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2014-189015

However, in recent years, NFC (Near Field Communication) represented by a non-contact IC (Integrated Circuit) card or the like has been put into practical use and widely used. The NFC uses a frequency band in the high frequency region compared to the position indicator. also, In recent years, wireless power transmission (contactless power transmission), which is being put into practical use, is also being studied in a manner of applying a high frequency band. The coil modules used for such wireless communication or wireless power transmission are designed to achieve maximum characteristics at a resonant frequency of 13.56 MHz or 6.78 MHz.

In such high-frequency wireless communication or wireless power transmission, since the magnetic flux converges around the loop coil becomes large, the magnetic flux easily leaks out of the loop coil. If the magnetic flux leaks, there is a possibility that the metal member (metal frame, battery, or the like) existing around it interferes with each other to cause an adverse effect. Therefore, further magnetic shielding is required.

It is an object of the present invention to provide a coil module having good magnetic shielding properties in wireless communication or wireless power transmission using a frequency band of 13.56 MHz or 6.78 MHz, and a method of manufacturing the same.

The present invention [1] includes a coil module that uses a wireless communication or wireless power transmission user in a frequency band of 13.56 MHz or 6.78 MHz, and includes a coil substrate including a substrate and a thickness direction disposed in the substrate a coil pattern on the side; the adhesive layer is formed on one side in the thickness direction of the coil substrate, and is formed of a heat-conductive particle, a soft magnetic particle and a resin-attached composition; and a magnetic layer provided on the adhesive layer It is formed on one side in the thickness direction and is composed of a magnetic composition containing soft magnetic particles and a resin.

The coil module according to the above aspect, wherein the content ratio of the soft magnetic particles to 100 parts by mass of the thermally conductive particles is 50 parts by mass or more and 2000 parts by mass or less or less in the adhesive layer. .

The present invention [3] includes a method of manufacturing a coil module, which is a method of manufacturing a coil module for wireless communication or wireless power transmission using a frequency band of 13.56 MHz or 6.78 MHz, and includes the following steps: preparing for containing soft magnetic particles And a magnetic layer formed by the magnetic composition of the resin; wherein the magnetic layer is provided by containing thermally conductive particles, soft a step of semi-hardening the layered body formed by the semi-hardened layer formed by the subsequent composition of the magnetic particles and the thermosetting resin; and contacting the semi-hardened layered layer with the above-mentioned coil pattern by the semi-hardened layer The method is performed by hot pressing on a coil substrate including a substrate and a coil pattern, thereby obtaining a coil module including a completely hardened back layer.

According to the coil module of the present invention obtained by the method for manufacturing a coil module of the present invention, the magnetic shielding property is good and the thickness can be reduced.

1‧‧‧ coil module

2‧‧‧Coil substrate

3‧‧‧Next layer

3a‧‧‧Semi-hardened layer

4‧‧‧Magnetic layer

4a‧‧‧Semi-hardened magnetic layer

5‧‧‧Base resin

6‧‧‧ coil pattern

7‧‧‧Wiring

8‧‧‧Semi-hardened layered layer

9‧‧‧thermal particles

10‧‧‧Soft magnetic particles

11‧‧‧ peeling substrate

15‧‧‧mounting table

16‧‧‧ Magnetic field probe

X‧‧‧ Wiring space

Y‧‧‧ Height of wiring

Z‧‧‧The distance between the upper surface of the coil pattern and the upper surface of the layer

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view showing an embodiment of a coil module of the present invention.

2A-G are diagrams showing the steps of manufacturing the coil module of Fig. 1, and Fig. 2A shows the step of preparing a semi-hardened magnetic layer, Fig. 2B shows the step of laminating a plurality of layers of the semi-hardened magnetic layer, and Fig. 2C shows the step of obtaining a magnetic layer. 2D shows a step of providing a semi-hardened adhesive layer on the magnetic layer, FIG. 2E shows a step of arranging the semi-hardened layered layer and the coil substrate, and FIG. 2F shows a step of thermally pressing the semi-hardened layered layer on the coil substrate. Figure 2G shows the steps of obtaining a coil module.

Fig. 3 is a schematic view showing a state in which the magnetic shielding property of the coil module is measured.

In FIG. 1, the up-down direction of the paper is the vertical direction (thickness direction, first direction), the upper side of the paper is the upper side (the one in the thickness direction, the first direction), and the lower side of the paper is the lower side (the other side in the thickness direction, The first direction is the other side). Regarding the drawings other than FIG. 1, the direction of FIG. 1 is also used as a reference.

The coil module 1 of the present invention includes the coil substrate 2, the subsequent layer 3, and the magnetic layer 4 in this order in the thickness direction as shown in FIG. The coil module 1 preferably includes a coil substrate 2, an adhesive layer 3, and a magnetic layer 4. The coil module 1 is, for example, transmitted between the power transmitting and receiving modules by wireless One of components such as a power receiving coil module used for wireless communication or wireless power transmission of a signal or electric power, and is an industrially usable device that is distributed as a separate component.

The coil substrate 2 is a circuit board used for wireless communication or wireless power transmission in a frequency band of 13.56 MHz or 6.78 MHz, and includes a base substrate 5 as an example of a substrate, and a coil pattern 6.

The base substrate 5 has an outer shape of the coil module 1, and has a sheet shape (including a film shape). Examples of the insulating material constituting the base substrate 5 include a glass epoxy substrate, a glass substrate, a ceramic substrate, a PET (Polyethylene Terephthalate) substrate, a fluororesin substrate, and a polyimide substrate. . From the viewpoint of flexibility, a PET substrate, a fluororesin substrate, a polyimide substrate, or the like is preferable.

The thickness of the base substrate 5 is, for example, 5 μm or more, preferably 8 μm or more, and is, for example, 100 μm or less, preferably 80 μm or less.

The coil pattern 6 is provided on the upper side (the side in the thickness direction) of the base substrate 5. Specifically, the coil pattern 6 is disposed on the upper surface of the base substrate 5 such that the lower surface of the coil pattern 6 is in contact with the upper surface of the base substrate 5.

The coil pattern 6 is formed by spirally forming one of the continuous wires 7 and may be either a circular shape (including an ellipse) or a rectangular shape.

Examples of the material constituting the wiring 7 include copper, nickel, tin, aluminum, iron, chromium, titanium, gold, silver, platinum, rhodium, and metals including these alloys; for example, polyaniline, polypyrrole, and poly Thiophene, polyacetylene, polyparaphenylene, polyphenylacetylene, polyacrylonitrile, poly A conductive polymer such as oxadiazole. These materials may be used alone or in combination of two or more. The metal is preferably exemplified by copper or silver, and more preferably copper.

The width of the wiring 7 is, for example, 10 μm or more, preferably 20 μm or more, and is, for example, 2000 μm or less, or preferably 1800 μm or less.

The gap (the pitch, the length of X shown in FIG. 2E) of the wiring 7 is, for example, 10 μm or more, preferably 20 μm or more, and is, for example, 3 mm or less, preferably 2 mm or less.

The thickness (height of the Y shown in FIG. 2E) of the wiring 7 is, for example, 5 μm or more, preferably 8 μm or more, and is, for example, 100 μm or less, preferably 80 μm or less.

Next, the layer 3 is provided on the upper side of the coil substrate 2. Specifically, the adhesive layer 3 is disposed on the upper surface of the base substrate 5 so as to cover the upper surface and the side surface of the coil pattern 6.

Next, the layer 3 is formed into a sheet shape from a subsequent composition containing the thermally conductive particles 9, the soft magnetic particles 10, and the resin.

Examples of the material for forming the thermally conductive particles include heat conductive materials such as nitrides, carbides, oxides, hydroxides, metals, and carbon-based materials.

Examples of the nitride include boron nitride, tantalum nitride, aluminum nitride, gallium nitride, chromium nitride, tungsten nitride, magnesium nitride, molybdenum nitride, and lithium nitride. Preferably, boron nitride is mentioned.

Examples of the carbide include cerium carbide, boron carbide, aluminum carbide, titanium carbide, and tungsten carbide.

Examples of the oxide include alumina (Alumina), magnesium oxide, and cerium oxide. Further, examples of the oxide include indium tin oxide, antimony tin oxide, and the like doped with a metal ion. Preferably, alumina is mentioned.

Examples of the hydroxide include aluminum hydroxide, magnesium hydroxide, and zinc hydroxide.

Examples of the metal include copper, gold, nickel, tin, iron, or alloys thereof.

Examples of the carbon-based material include carbon black, graphite, diamond, fullerene, carbon nanotube, carbon nanofiber, carbon nanohorn, spiral carbon fiber, and nano coil.

These thermally conductive particles may be used alone or in combination of two or more.

Among these thermally conductive particles, a nitride or an oxide is preferable, and a nitride is more preferable, and boron nitride is more preferable.

Examples of the shape of the thermally conductive particles include a block shape, a flat shape, and a needle shape. on The block shape includes, for example, a spherical shape, a rectangular parallelepiped shape, a broken shape, an arc shape, an agglomerate, or the like shape.

The average particle diameter (the average value of the maximum length) of the thermally conductive particles is, for example, 1 μm or more, preferably 3 μm or more, and is, for example, 200 μm or less, or preferably 150 μm or less. The average particle size is based on the particle size distribution measured by the particle size distribution measurement in the laser diffraction-scattering method, the average particle diameter on a volume basis, more specifically, the D50 value (accumulated 50% median diameter) The form is obtained.

The mass ratio of the thermally conductive particles in the composition is, for example, 4% by mass or more, preferably 7% by mass or more, more preferably 10% by mass or more, and still more preferably 20% by mass or more, in terms of solid content. For example, it is 80% by mass or less, preferably 70% by mass or less, more preferably 60% by mass or less, and still more preferably 50% by mass or less. In addition, the volume ratio of the thermally conductive particles in the composition is, for example, 10% by volume or more, preferably 15% by volume or more, more preferably 20% by volume or more, and, for example, 65% by volume or less, in terms of solid content. It is preferably 50% by volume or less, more preferably 35% by volume or less. By setting the content ratio of the thermally conductive particles to the above range, the adhesion of the adhesive layer 3 and the heat dissipation property can be improved.

Examples of the soft magnetic material constituting the soft magnetic particles include magnetic stainless steel (Fe-Cr-Al-Si alloy), Fe-Si-Al alloy, Fe-Ni alloy, beryllium copper (Fe-Cu-Si alloy), Fe-Si alloy, Fe-Si-B (-Cu-Nb) alloy, Fe-Si-Cr-Ni alloy, Fe-Si-Cr alloy, Fe-Si-Al-Ni-Cr alloy, ferrite, and the like. These soft magnetic particles may be used alone or in combination of two or more.

Among these, in terms of magnetic properties, a Fe-Si-Al alloy is preferable.

The soft magnetic particles have a flat shape (plate shape), that is, a shape having a thin thickness and a wide surface. The flatness (flatness) of the soft magnetic particles is, for example, 8 or more, preferably 15 or more, and is, for example, 500 or less, preferably 450 or less. The flatness ratio is calculated, for example, in the form of an aspect ratio obtained by dividing the average particle diameter of the soft magnetic particles by the average thickness of the soft magnetic particles.

The average particle diameter (the average value of the maximum length) of the soft magnetic particles is, for example, 3.5 μm or more, preferably 10 μm or more, and is, for example, 200 μm or less, preferably 150 μm or less. The average thickness is, for example, 0.1 μm or more, preferably 0.2 μm or more, and is, for example, 3.0 μm or less, or preferably 2.5 μm or less. By adjusting the flatness ratio, the average particle diameter, the average thickness, and the like of the soft magnetic particles, the influence of the demagnetizing field by the soft magnetic particles can be made small, and as a result, the magnetic permeability of the soft magnetic particles can be increased. Further, in order to make the size of the soft magnetic particles uniform, soft magnetic particles which have been classified by a sieve or the like may be used as needed.

The mass ratio of the soft magnetic particles in the composition is, for example, 10% by mass or more, preferably 15% by mass or more, more preferably 20% by mass or more, and still more preferably 30% by mass or more, in terms of solid content. For example, it is 90% by mass or less, preferably 80% by mass or less, more preferably 70% by mass or less, and still more preferably 50% by mass or less. In addition, the volume ratio of the soft magnetic particles in the composition is, for example, 5% by volume or more, preferably 10% by volume or more, more preferably 15% by volume or more, and for example, 60% by volume or less, in terms of solid content. It is preferably 45 vol% or less, more preferably 30 vol% or less. Thereby, the magnetic properties of the adhesive layer 3 can be improved.

Then, the total mass ratio of the thermally conductive particles and the soft magnetic particles in the composition is, for example, 35 mass% or more, preferably 40 mass% or more, more preferably 45 mass% or more, and further preferably more than the solid content. 50% by mass, for example, is 95% by mass or less, preferably 90% by mass or less, more preferably 85% by mass or less, still more preferably 80% by mass or less. In addition, the total volume ratio of the thermally conductive particles and the soft magnetic particles in the composition is, for example, 15% by volume or more, preferably 20% by volume or more, more preferably 30% by volume or more, for example, 70% in terms of solid content. The volume % or less is preferably 60% by volume or less, more preferably 50% by volume or less. Thereby, the adhesion and magnetic shielding properties can be further improved.

The mass ratio of the soft magnetic particles to 100 parts by mass of the thermally conductive particles is, for example, 50 parts by mass or more, preferably 100 parts by mass or more, and further, for example, 2,000 parts by mass or less, preferably 1800 parts by mass or less, more preferably 1,000 or more. Below the mass. Also, soft magnetic particles are relatively The volume ratio of 100 parts by volume of the thermally conductive particles is, for example, 30 parts by volume or more, preferably 40 parts by volume or more, and further, for example, 650 parts by volume or less, preferably 550 parts by volume or less, more preferably 500 parts by volume or less. By setting the content ratio of the soft magnetic particles to the above range, the heat dissipation property and the magnetic properties of the adhesive layer 3 can be improved in a well-balanced manner, and as a result, the magnetic shielding property of the coil module 1 can be further improved. The temperature change when a large current is applied can be suppressed.

In the present invention, the volume ratio of each component such as thermally conductive particles and soft magnetic particles is calculated based on the theoretical volume obtained by dividing the mass of each component by the specific gravity of the component. The specific gravity (true specific gravity) of each component is obtained by a catalog value or a known measurement method (for example, Archimedes' method).

Examples of the binder resin include a thermosetting resin and a thermoplastic resin.

Examples of the thermosetting resin include an epoxy resin, a phenol resin, a melamine resin, a vinyl ester resin, a cyanoester resin, a maleimide resin, and a polyoxyxylene resin. The thermosetting resin is preferably an epoxy resin or a phenol resin, and more preferably an epoxy resin or a phenol resin.

Examples of the epoxy resin include bisphenol A epoxy resin, bisphenol F epoxy resin, modified bisphenol A epoxy resin, modified bisphenol F epoxy resin, and biphenyl epoxy. a bifunctional epoxy resin such as a resin; for example, a phenol novolak type epoxy resin, a cresol novolak type epoxy resin, a trishydroxyphenylmethane type epoxy resin, a tetraphenol ethyl ethane type epoxy resin, a dicyclopentane A trifunctional or higher polyfunctional epoxy resin such as a diene type epoxy resin. These epoxy resins may be used alone or in combination of two or more.

Preferred examples thereof include a cresol novolac type epoxy resin (for example, the following structural formula (1)) and a bisphenol A type epoxy resin (for example, the following structural formula (2)), and more preferably a cresol novolac A combination of a varnish type epoxy resin and a bisphenol A type epoxy resin. By using these epoxy resins, it is excellent in adhesiveness, film formability, and the like.

[Chemical 1]

Further, n of the formula (1) and the formula (2) independently represents the degree of polymerization of the monomer.

The epoxy equivalent of the epoxy resin is, for example, 230 g/eq. or less, preferably 210 g/eq. or less, and further, for example, 10 g/eq. or more, preferably 50 g/eq. or more.

The viscosity of the epoxy resin (150 ° C) is, for example, 1.0 Pa. Below s, preferably 0.5 Pa. s below, again, is 0.01Pa. s above. Viscosity is determined by an ICI viscometer.

The phenolic resin is a thermosetting resin which is a curing agent of an epoxy resin, and examples thereof include a phenol novolak resin, a cresol novolak resin, a phenol aralkyl resin, a phenol coexying benzene resin, and dicyclopentadiene. A trifunctional or higher polyfunctional phenol resin such as a phenol resin or a resol resin. These phenolic resins may be used singly or in combination of two or more.

The phenol-coextensive benzene resin is preferably exemplified, and specific examples thereof include compounds represented by the following structural formula (3).

Further, n each independently represents the degree of polymerization of the monomer.

The hydroxyl group equivalent of the phenol resin is, for example, 230 g/eq. or less, preferably 210 g/eq. or less, and further, for example, 10 g/eq. or more, preferably 50 g/eq. or more.

The viscosity of the phenolic resin (150 ° C) is, for example, 1.0 Pa. Below s, preferably 0.5 Pa. s below, again, is 0.01Pa. s above.

Examples of the thermoplastic resin include an acrylic resin, a vinyl acetate resin, and a polyvinyl alcohol resin. Preferably, an acrylic resin is mentioned.

The acrylic resin is, for example, one or two or more kinds of alkyl (meth)acrylates having a linear or branched alkyl group as a monomer component, and obtained by polymerizing the monomer component. Acrylic polymer or the like. Further, "(meth)acrylic acid" means "acrylic acid and/or methacrylic acid".

Examples of the alkyl group include a methyl group, an ethyl group, a propyl group, an isopropyl group, a n-butyl group, a tert-butyl group, an isobutyl group, a pentyl group, an isopentyl group, a hexyl group, a heptyl group, a cyclohexyl group, and 2 -ethylhexyl, octyl, isooctyl, decyl, isodecyl, decyl, isodecyl, undecyl, lauryl, tridecyl, tetradecyl, stearyl, octadecyl An alkyl group such as an alkyl group or a dodecyl group having 1 to 20 carbon atoms. Preferably, an alkyl group having 1 to 6 carbon atoms is used.

The acrylic polymer may also be a copolymer of an alkyl (meth)acrylate and another monomer.

Examples of the other monomer include glycidyl group-containing monomers such as glycidyl acrylate and glycidyl methacrylate; for example, acrylic acid, methacrylic acid, carboxyethyl acrylate, carboxy amyl acrylate, and itaconic acid. a carboxyl group-containing monomer such as maleic acid, fumaric acid or crotonic acid; for example, an acid anhydride monomer such as maleic anhydride or itaconic anhydride; for example, 2-hydroxyethyl (meth)acrylate or 2-(meth)acrylic acid Hydroxypropyl ester, 4-hydroxybutyl (meth)acrylate, 6-hydroxyhexyl (meth)acrylate, 8-hydroxyoctyl (meth)acrylate, 10-hydroxydecyl (meth)acrylate, (A) a hydroxyl group-containing monomer such as 12-hydroxylauryl acrylate or (4-hydroxymethylcyclohexyl)-methyl acrylate; for example, styrenesulfonic acid, allylsulfonic acid, 2-(methyl)acrylamide -2-methylpropanesulfonic acid, (meth)acrylamide, propanesulfonic acid, (meth)acrylic acid a sulfonic acid group-containing monomer such as propyl ester or (meth)acryloxynaphthalenesulfonic acid; a phosphate group-containing monomer such as 2-hydroxyethyl acryloylphosphoric acid phosphate; for example, a styrene monomer; for example, acrylonitrile Wait. These monomers may be used alone or in combination of two or more. Among these, acrylonitrile is preferable.

Further, the acrylic resin preferably has at least one of a carboxyl group and a hydroxyl group. More preferably, it has a carboxyl group and a hydroxyl group.

The weight average molecular weight of the acrylic resin is, for example, 1 × 10 ⁵ or more, preferably 3 × 10 ⁵ or more, and for example, 1 × 10 ⁶ or less. Further, the weight average molecular weight is measured by gel permeation chromatography (GPC) based on a standard polystyrene equivalent value.

The content ratio of the resin in the composition is, for example, 5% by mass or more, preferably 10% by mass or more, more preferably 15% by mass or more, and still more preferably 20% by mass or more, in terms of the solid content. For example, it is 65% by mass or less, preferably 60% by mass or less, more preferably 55% by mass or less, and still more preferably 50% by mass or less. By setting the content ratio of the binder resin to the above range, the adhesion can be further improved.

Next, the composition is preferably a thermosetting resin and a thermoplastic resin in combination. More preferably, an epoxy resin and a phenol resin are contained as a thermosetting resin, and an acrylic resin is contained as a thermoplastic resin. Therefore, when the plurality of layers of the semi-hardened adhesive layer 3a described below are laminated and hot-pressed, the gap between the interfaces of the semi-hardened adhesive layers 3a or the gap between the semi-hardened adhesive layer 3a and the coil substrate 2 can be filled. The magnetic layer 4 and the coil substrate 2 are more reliably and firmly attached.

In this case, the content ratio of the epoxy resin in the resin is, for example, 5% by mass or more, preferably 10% by mass or more, more preferably 25% by mass or more, and further, for example, 50% by mass or less, preferably 40% by mass or less, more preferably 35% by mass or less. The content ratio of the phenolic resin in the resin is, for example, 5% by mass or more, preferably 10% by mass or more, more preferably 25% by mass or more, and further, for example, 50% by mass or less, preferably 40% by mass or less. More preferably, it is 35 mass% or less. The content ratio of the acrylic resin in the resin is, for example, 25% by mass or more, preferably 30% by mass or more, more preferably 35% by mass or more, and for example, 80% by mass or less, preferably 70% by mass or less. Better than 50 quality %.

The composition then preferably further contains a heat hardening catalyst.

The thermosetting catalyst is a catalyst that promotes curing of the resin by heating, and examples thereof include an imidazole compound, a triphenylphosphine compound, a triphenylborane compound, an amine group-containing compound, and an acid anhydride. A compound or the like. Preferably, an imidazole compound is mentioned.

Examples of the imidazole-based compound include 2-phenylimidazole (trade name; 2PZ), 2-ethyl-4-methylimidazole (trade name; 2E4MZ), and 2-methylimidazole (trade name; 2MZ). 2-undecylimidazole (trade name; C11Z), 2-phenyl-1H-imidazole 4,5-dimethanol (trade name; 2PHZ-PW), 2,4-diamino-6-(2' -methylimidazolyl (1)') ethyl-symmetric three - an isocyanuric acid adduct (trade name; 2MAOK-PW), etc. (the above-mentioned trade names are all manufactured by Shikoku Chemicals Co., Ltd.).

These thermosetting catalysts may be used alone or in combination of two or more.

The content ratio of the heat-hardening catalyst is, for example, 0.1 part by mass or more, preferably 0.3 parts by mass or more, and further, for example, 5 parts by mass or less, preferably 3 parts by mass or less, based on 100 parts by mass of the resin. By setting the content ratio of the thermosetting catalyst to the above range, the subsequent composition can be heat-cured at a low temperature for a short period of time and then carried out.

The composition may then optionally contain other additives as needed. Examples of the additive include commercially available or known ones such as a crosslinking agent and an inorganic filler.

In the adhesive layer 3, the distance from the upper surface of the coil pattern 6 (the surface on the one side in the thickness direction) to the upper surface of the subsequent layer 3 (the length of Z shown in FIG. 1) is, for example, 100 μm or less, preferably 80 μm or less. Further, for example, it is 1 μm or more, and preferably 3 μm or more.

Further, the maximum thickness of the layer 3 (that is, the distance between the upper surface of the base substrate 5 and the upper surface of the layer 3) is, for example, 200 μm or less, preferably 150 μm or less, and further, for example, 6 μm or more, preferably 9 μm or more. .

The magnetic layer 4 is provided on the upper side of the adhesive layer 3. Specifically, the magnetic layer 4 is magnetic The lower surface of the layer 4 is disposed on the upper surface of the adhesive layer 3 in contact with the upper surface of the adhesive layer 3.

The magnetic layer 4 is formed into a sheet shape from a magnetic composition containing soft magnetic particles 10 and a resin.

The soft magnetic particles 10 are exemplified as the soft magnetic particles 10 exemplified in the composition. The magnetic properties are preferably Fe-Si-Al alloys.

The mass ratio of the soft magnetic particles in the magnetic composition is, for example, 80% by mass or more, preferably 83% by mass or more, more preferably 85% by mass or more, and, for example, 98% by mass or less, in terms of solid content. The content is preferably 95% by mass or less, more preferably 92% by mass or less. In addition, the volume ratio of the soft magnetic particles in the magnetic composition is, for example, 40% by volume or more, preferably 45% by volume or more, more preferably 50% by volume or more, and still more preferably 60% by volume or more, in terms of solid content. For example, it is 90% by volume or less, preferably 80% by volume or less, and more preferably 70% by volume or less. The magnetic layer 4 is excellent in magnetic properties by setting the content ratio of the soft magnetic particles to the above lower limit or more. On the other hand, when it is set to the above upper limit or less, the magnetic composition is excellent in film formability.

The resin (hereinafter referred to as a resin for a magnetic layer) contained in the magnetic composition may, for example, be a thermosetting resin or a thermoplastic resin.

The thermosetting resin may be a thermosetting resin exemplified as the resin, and an epoxy resin or a phenol resin is preferable.

The thermoplastic resin exemplified as the resin is preferably used as the thermoplastic resin, and an acrylic resin is preferable.

The resin for the magnetic layer preferably contains an epoxy resin, a phenol resin, and an acrylic resin.

In the resin for a magnetic layer, the epoxy resin preferably contains only an epoxy resin having three or more functional groups (for example, a glycidyl group) (for example, the above-mentioned polyfunctional epoxy resin). In other words, the epoxy resin in the resin for the magnetic layer does not substantially contain two functional groups. Epoxy resin (for example, the above-mentioned bifunctional epoxy resin).

The term "substantially no bifunctional epoxy resin" means that the content ratio of the epoxy resin having two functional groups in the entire epoxy resin is, for example, 1.0% by weight or less, preferably 0.5% by mass or less, more preferably Good is 0% by mass.

Examples of such an epoxy resin include a polyfunctional epoxy resin exemplified as the resin, and a cresol novolak epoxy resin is preferable.

The phenol resin preferably contains only a phenol resin (polyfunctional phenol resin) having three or more functional groups (for example, a hydroxyl group) in the molecule. In other words, the phenolic resin in the resin for a magnetic layer does not substantially contain a phenolic resin having two functional groups.

The content of the phenolic resin having two functional groups in the entire phenolic resin is, for example, 1.0% by weight or less, preferably 0.5% by mass or less, and more preferably 0.5% by mass or less. Good is 0% by mass.

The phenol-based resin may be a polyfunctional phenol-based resin exemplified as the resin, and a phenol-stretched benzene resin is preferred.

It is particularly preferable that the resin for the magnetic layer contains only a polyfunctional epoxy resin and a polyfunctional phenol resin as the thermosetting resin. That is, it does not contain a bifunctional epoxy resin or a bifunctional phenol resin. Thereby, a uniform and strong hardening resin is formed in the magnetic layer 4, so that the soft magnetic particles can be contained in the magnetic layer 4 at a high ratio, and the repelling of the soft magnetic particles or the resin elasticity can be suppressed. The void of the magnetic layer 4 is generated (bounced back). As a result, the magnetic properties of the magnetic layer 4 can be further improved.

The content ratio of the resin for the magnetic layer in the magnetic composition is, for example, 2% by mass or more, preferably 5% by mass or more, more preferably 8% by mass or more, and further, for example, 20% by mass or less, in terms of solid content. It is preferably 17% by mass or less, and more preferably 15% by mass or less. When the content ratio of the resin for the magnetic layer is within the above range, the magnetic layer 4 is excellent in film formability and magnetic properties.

Moreover, the total content of the epoxy resin and the phenol resin (that is, the thermosetting resin), 100 parts by mass of the component other than the soft magnetic particles from which the soft magnetic particles are removed, for example, 20 parts by mass or more, preferably 30 parts by mass or more, more preferably more than 50 parts by mass, and further, for example, 99 parts by mass or less, preferably 90 parts by mass or less, more preferably 80 parts by mass or less, still more preferably 60 parts by mass or less. By setting the total content of the epoxy resin and the phenol resin to the above range, the soft magnetic particles can be contained in the magnetic layer 4 at a high ratio, and the rebound can be suppressed, and as a result, the magnetic layer can be made. The magnetic properties of 4 are further improved.

Further, the components other than the soft magnetic particles include, more specifically, a component for a magnetic layer, a thermosetting catalyst, and an additive (described below) which are added as needed (solid content), and do not contain soft. Magnetic particles and solvents.

The content ratio of the epoxy resin in the resin for a magnetic layer is, for example, 5% by mass or more, preferably 10% by mass or more, more preferably 25% by mass or more, and for example, 50% by mass or less, preferably 40% by mass. Hereinafter, it is more preferably 35 mass% or less. The content ratio of the phenol resin in the resin for a magnetic layer is, for example, 5% by mass or more, preferably 10% by mass or more, more preferably 25% by mass or more, and for example, 50% by mass or less, preferably 40% by mass. Hereinafter, it is more preferably 35 mass% or less. The content ratio of the acrylic resin in the resin for a magnetic layer is, for example, 25% by mass or more, preferably 30% by mass or more, more preferably 35% by mass or more, and for example, 80% by mass or less, preferably 70% by mass. Hereinafter, it is more preferably less than 50% by mass. When the content ratio of the acrylic resin is within the above range, the rebound of the magnetic layer 4 can be suppressed. Further, the viscosity of the magnetic composition can be improved to improve the film formability. Further, the alignment of the soft magnetic particles in the resin after the film formation can be improved. As a result, the magnetic properties can be further improved.

The magnetic composition preferably further contains a thermosetting catalyst.

As the thermosetting catalyst, a thermosetting catalyst exemplified in the subsequent composition can be exemplified. Preferably, an imidazole compound is mentioned.

The content ratio of the thermosetting catalyst is 100 parts by mass relative to the resin for the magnetic layer. For example, it is 0.1 part by mass or more, preferably 0.3 part by mass or more, and further, for example, 5 parts by mass or less, preferably 3 parts by mass or less. By setting the content ratio of the thermosetting catalyst to the above range, the magnetic composition can be heat-cured at a low temperature and for a short period of time.

The magnetic composition preferably further contains a dispersing agent. The soft magnetic particles are uniformly dispersed in the magnetic layer 4 by causing the magnetic composition to contain a dispersing agent.

The dispersing agent is preferably a polyether phosphate or the like from the viewpoint of dispersibility and magnetic properties.

Specific examples of the polyether phosphate include the HIPLAAD series ("ED-152", "ED-153", "ED-154", "ED-118", "ED-174", "" ED-251") and so on.

The acid value of the polyether phosphate is, for example, 10 or more, preferably 15 or more, and is, for example, 200 or less, preferably 150 or less. The acid value is determined by a neutralization titration method or the like.

The content ratio of the dispersant is 0.1 parts by mass or more, preferably 0.3 parts by mass or more, based on 100 parts by mass of the resin for the magnetic layer. Further, it is 5 parts by mass or less, preferably 3 parts by mass or less.

The magnetic composition preferably further contains a rheology control agent. The soft magnetic particles can be uniformly dispersed in the magnetic layer 4 by including the rheological control agent in the magnetic composition.

The rheology control agent exhibits a high viscosity when the shearing force (shearing speed) is low, and a low viscosity thixotropy when the shearing force (shearing speed) is high. compound of.

Examples of the rheology control agent include an organic rheology control agent and an inorganic rheology control agent. Preferably, an organic rheology control agent is mentioned.

Examples of the organic rheology control agent include modified urea, urea-modified polyamine, fatty acid decylamine, polyurethane, and polymer urea derivative. The modified urea, the urea-modified polyamine, and the fatty acid guanamine are preferable, and a urea-modified polyamine is more preferable.

Examples of the inorganic rheology control agent include cerium oxide, calcium carbonate, and swelling. Stone and so on.

Specific examples of the rheology control agent include "BYK-410", "BYK-430", and "BYK-431" by BYK-Chemie Co., Ltd.; for example, "Disparlon PFA-131" by Nanben Chemical Co., Ltd.; for example; "Aerosil VP NK200", "Aerosil R976S", "Aerosil COK84", etc. from Aerosil Corporation of Japan.

These rheology control agents may be used alone or in combination of two or more.

The content ratio of the rheology control agent is, for example, 0.1 part by mass or more, preferably 0.5 part by mass or more, and further, for example, 10 parts by mass or less, based on 100 parts by mass of the resin for the magnetic layer. It is preferably 5 parts by mass or less.

The magnetic composition may further contain other additives as needed. Examples of the additive include commercially available or known ones such as a crosslinking agent and an inorganic filler.

The average thickness of the magnetic layer 4 is, for example, 5 μm or more, preferably 10 μm or more, and is, for example, 500 μm or less, or preferably 250 μm or less.

2. Manufacturing method of coil module

A method of manufacturing the coil module 1 will be described with reference to Figs. 2A to 2G.

The manufacturing method of the coil module 1 includes, for example, a magnetic layer preparing step of preparing a magnetic layer 4, and a laminated body forming step of obtaining a semi-hardened layered layer 8 by providing a semi-hardened back layer 3a of the magnetic layer 4; In a pressing step, the semi-hardened layered body 8 is heat-pressed to the coil substrate 2. Hereinafter, the steps will be described.

(magnetic layer preparation step)

In the magnetic layer preparation step, the magnetic layer 4 is prepared.

The magnetic layer preparation step includes, for example, a step of preparing a magnetic composition solution by dissolving or dispersing the magnetic composition in a solvent; by applying a magnetic composition solution to the surface of the release substrate 11 and drying it The step of obtaining a magnetic layer (semi-hardened magnetic layer 4a) in a semi-hardened state; and a step of laminating a plurality of semi-hardened magnetic layers 4a and performing hot pressing.

First, the magnetic composition is dissolved or dispersed in a solvent. Thereby, a magnetic composition solution was prepared.

The magnetic composition is prepared by mixing the components described in the magnetic layer 4 at the above ratios.

Examples of the solvent include ketones such as acetone and methyl ethyl ketone (MEK); esters such as ethyl acetate; and ethers such as propylene glycol monomethyl ether; for example, N,N-dimethylformamide, and the like. An organic solvent such as guanamine. Further, examples of the solvent include water; for example, an aqueous solvent such as an alcohol such as methanol, ethanol, propanol or isopropanol.

The amount of the solid content in the magnetic composition solution is, for example, 10% by mass or more, preferably 30% by mass or more, and for example, 90% by mass or less, preferably 70% by mass or less.

Then, as shown in FIG. 2A, the magnetic composition solution is applied onto the surface of the release substrate 11 (isolation film, core material, etc.) and dried.

Examples of the coating method include blade coating, roll coating, screen coating, and gravure coating.

The drying temperature is, for example, 50° C. or higher and 150° C. or lower (preferably 60° C. or higher and 120° C. or lower), and the drying time is, for example, 1 minute or longer and 5 minutes or shorter.

Examples of the separator include a polyethylene terephthalate (PET) film, a polyethylene film, a polypropylene film, and paper. These surfaces are, for example, subjected to release treatment such as a fluorine-based release agent, an acrylic long-chain alkyl ester release agent, or a polyoxynitride-based release agent.

Examples of the core material include a plastic film (for example, a polyimide film, a polyester film, a polyethylene terephthalate film, a polyethylene naphthalate film, a polycarbonate film, etc.), and a metal. A film (for example, an aluminum foil or the like), a resin substrate reinforced with a non-woven fiber such as glass fiber or plastic, a polyoxymethylene plate, a glass substrate, or the like.

The average thickness of the release substrate 11 is, for example, 1 μm or more and 500 μm or less.

Thereby, the semi-hardened magnetic layer 4a in a semi-hardened state (B stage) is obtained.

The so-called semi-hardened state (stage B) means, for example, soluble at room temperature (25 ° C) The state between the unhardened state of the agent (stage A) and the fully hardened state (stage C), and means that the hardening and gelation progress slightly, although it is swollen in the solvent but not completely dissolved, and is heated by heating. Softened but not molten state.

The average thickness of the semi-hardened magnetic layer 4a is, for example, 5 μm or more, preferably 10 μm or more, and is, for example, 500 μm or less, or preferably 250 μm or less.

Then, as shown in FIG. 2B, a plurality of semi-hardened magnetic layers 4a are prepared, and a plurality of semi-hardened magnetic layers 4a are hot-pressed in the thickness direction.

The hot pressing can be carried out by using a known press machine, and examples thereof include a parallel plate press machine and the like. By heat-pressing the plurality of semi-hardened magnetic layers 4a, the soft magnetic particles can be filled in the magnetic layer 4 at a high ratio, and the flat soft magnetic particles can be aligned in the plane direction. Therefore, the magnetic characteristics can be further improved.

The number of laminated sheets of the semi-hardened magnetic layer 4a is two layers in FIG. 2B, but is not limited to FIG. 2B, and is, for example, two or more layers, and is, for example, 20 or less, preferably 10 or less. Thereby, the magnetic layer 4 can be adjusted to a desired thickness.

The heating temperature is, for example, 130 ° C or higher, preferably 150 ° C or higher, and is, for example, 250 ° C or lower, preferably 200 ° C or lower.

The hot pressing time is, for example, 1 minute or longer, preferably 2 minutes or longer, and for example, 24 hours or shorter, preferably 2 hours or shorter.

The pressure is, for example, 1 MPa or more, preferably 3 MPa or more, and is, for example, 200 MPa or less, preferably 100 MPa or less.

Thereby, as shown in FIG. 2C, the semi-hardened magnetic layer 4a is heat-hardened to obtain the magnetic layer 4 in a completely hardened state (C stage). Further, the plurality of layers of the semi-hardened magnetic layer 4a are integrated by heating to form a magnetic layer 4, and the interface of the plurality of layers of the semi-hardened magnetic layer 4a is substantially not observed in the magnetic layer 4.

The real part μ' of the complex magnetic permeability of the magnetic layer 4 is, for example, 50 or more, preferably 60 or more, and is, for example, 250 or less. In the present invention, the real part of the complex magnetic permeability μ' is used as an impedance score. The analyzer ("4294A" manufactured by Agilent Co., Ltd.) was measured by a single coil method (frequency 13.56 MHz).

The magnetic layer 4 is preferably arranged such that the flat soft magnetic particles 10 contained in the magnetic layer 4 are arranged in the two-dimensional in-plane direction of the magnetic layer 4 as shown in FIG. In other words, the longitudinal direction of the flat soft magnetic particles 10 (the direction orthogonal to the thickness direction) is aligned in the direction of the surface of the magnetic layer 4. Thereby, the magnetic layer 4 is filled with soft magnetic particles at a high ratio and is excellent in magnetic properties. Further, thinning of the magnetic layer 4 is achieved.

(layer formation step)

In the laminated body forming step, as shown in FIG. 2D, a semi-hardened adhesive layer 3a is provided on the magnetic layer 4.

The layer forming step includes, for example, a step of preparing a thermosetting adhesive composition solution by dissolving or dispersing the thermosetting adhesive composition in a solvent; by applying the thermosetting adhesive composition solution to the peeling The surface of the substrate is dried to obtain a semi-hardened adhesive layer (semi-hardened adhesive layer 3a); and the semi-hardened adhesive layer 3a is laminated on the upper surface of the magnetic layer 4 and pressurized.

First, the thermosetting composition is dissolved or dispersed in a solvent. Thereby, a thermosetting adhesive composition solution was prepared.

The thermosetting adhesive composition is prepared by mixing the components described in the adhesive layer 3 at the above ratio, and in particular, by mixing at least the thermally conductive particles, the soft magnetic particles, and the thermosetting resin. In other words, the thermosetting adhesive composition contains thermally conductive particles, soft magnetic particles, and thermosetting resin, and the thermosetting adhesive composition preferably contains thermally conductive particles, soft magnetic particles, thermosetting resin, and thermoplastic resin. The thermosetting adhesive composition contains thermally conductive particles, soft magnetic particles, an epoxy resin, a phenol resin, and an acrylic resin.

As the solvent, a solvent exemplified in the magnetic composition solution can be exemplified.

The amount of the solid content in the thermosetting and then the composition solution is, for example, 10% by mass. The upper portion is preferably 30% by mass or more, and is, for example, 90% by mass or less, preferably 70% by mass or less.

Then, the thermosetting adhesive composition solution is applied onto the surface of the release substrate (separator, core material, etc.) and dried.

Examples of the coating method and the release substrate include a coating method exemplified in the magnetic layer preparation step and a release substrate.

The drying temperature is, for example, 50° C. or higher and 150° C. or lower (preferably 60° C. or higher and 120° C. or lower), and the drying time is, for example, 1 minute or longer and 5 minutes or shorter.

Thereby, the semi-hardened adhesive layer 3a in a semi-hardened state (B-stage) is obtained.

The average thickness of the semi-hardened adhesive layer 3a is, for example, 5 μm or more, preferably 10 μm or more, and is, for example, 500 μm or less, or preferably 250 μm or less.

Then, a plurality of semi-hardened adhesive layers 3a are prepared on the upper surface of the magnetic layer 4, and the plurality of semi-hardened adhesive layers 3a are pressed in the thickness direction.

The number of laminated sheets of the semi-hardened adhesive layer 3a is two layers in FIG. 2D, but is not limited to FIG. 2D, and is, for example, two or more layers, and is, for example, 20 or less layers, preferably five or less layers. Thereby, the adhesive layer 3 can be adjusted to a desired thickness.

The pressure is, for example, 0.01 MPa or more, preferably 0.1 MPa or more, and further, for example, 50 MPa or less, preferably 10 MPa or less, more preferably 3 MPa or less.

When pressurized, it can also be heated as needed.

In the case of heating, the heating temperature in this case is within the range of the temperature at which the semi-hardened layer 3a is not completely cured, and may be, for example, in the same range as the drying temperature of the semi-curable composition solution.

Thereby, as shown in FIG. 2D, a semi-hardened layered layer 8 of a semi-hardened back layer 3a is provided on the upper surface of the magnetic layer 4.

(hot pressing step)

The hot pressing step heat-presses the semi-hardened layered layer body 8 to the coil substrate 2.

First, as shown in FIG. 2E, the coil substrate 2 is prepared. The coil substrate 2 can be formed by a known or commercially available one. For example, the coil pattern 6 of the coil substrate 2 is formed by an addition method or a subtractive method.

Then, the semi-hardened subsequent laminated body 8 is placed above the coil substrate 2 with the semi-hardened adhesive layer 3a facing the coil pattern 6 with a space therebetween.

Then, as shown in FIG. 2F, the laminated body 8 is heated and semi-hardened, and pressed (pressurized) downward.

The hot pressing can be carried out by using a known press machine, and examples thereof include a parallel plate press machine and the like.

The heating temperature is, for example, 130 ° C or higher, preferably 150 ° C or higher, and is, for example, 250 ° C or lower, preferably 200 ° C or lower.

The hot pressing time is, for example, 1 minute or longer, preferably 2 minutes or longer, and for example, 24 hours or shorter, preferably 2 hours or shorter.

The pressure is, for example, 0.01 MPa or more, preferably 0.1 MPa or more, and further, for example, 50 MPa or less, preferably 10 MPa or less, more preferably 3 MPa or less.

Thereby, the coil pattern 6 is buried in the semi-hardened back layer 3a while the semi-hardened back layer 3a becomes the adhesive layer 3 in the fully cured state (C stage), and the layer 3 follows the coil substrate 2 and the magnetic layer 4. That is, the surface (upper surface and side surface) of the coil pattern 6 and the adhesion layer 3 in which the upper surface of the base substrate 5 exposed from the coil pattern 6 is completely cured are covered. At this time, the plurality of layers of the semi-hardened layer 3a are integrated by heat pressing to form a layer of the subsequent layer 3, and the interface of the plurality of layers of the semi-hardened layer 3a is substantially not observed in the layer 3.

As a result, as shown in FIG. 2G, the coil substrate 2, the adhesive layer 3 which is provided on the upper surface of the coil substrate 2 and is completely cured, and the magnetic layer which is provided on the upper surface of the adhesive layer 3 and are completely hardened are obtained. 4 coil module 1.

The real part μ' of the complex magnetic permeability of the layer 3 is, for example, 50 or more, preferably 60 or more, and is, for example, 200 or less.

The thermal conductivity of the layer 3 is, for example, 1.0 W/mK or more, preferably 2.0 W/mK or more, and is, for example, 100 W/mK or less. Thereby, the reduction in communication characteristics can be suppressed. The method of measuring the thermal conductivity of layer 3 is described in detail in the examples.

Next, the layer 3 is preferably arranged such that the flat soft magnetic particles 10 contained in the adhesive layer 3 are arranged in the in-plane direction of the two-dimensional layer of the subsequent layer 3 as shown in FIG. That is, the longitudinal direction of the flat soft magnetic particles (the direction orthogonal to the thickness direction) is aligned along the surface direction of the subsequent layer 3. Thereby, the layer 3 can achieve a more excellent convergence of the magnetic flux.

Further, in the above-described manufacturing method, a plurality of the semi-hardened magnetic layer 4a and the semi-hardened adhesive layer 3a are laminated and hot-pressed, but for example, one of the semi-hardened magnetic layer 4a and the semi-hardened adhesive layer 3a may be used. (single layer) is subjected to hot pressing.

Further, in the embodiment of Fig. 1, the coil pattern 6 is formed only on the upper surface of the base substrate 5. However, for example, the coil pattern 6 may be formed on the upper surface and the lower surface of the base substrate 5.

Further, according to the coil module 1, since the magnetic layer 4 including the soft magnetic particles 10 is included, the magnetic flux generated during communication or power transmission can be converged by the magnetic layer 4. Further, since the adhesion layer 3 containing the soft magnetic particles 10 is included between the coil substrate 2 and the magnetic layer 4, the adhesion layer 3 can also converge the magnetic flux. Thereby, good magnetic shielding properties are exhibited. In particular, since the adhesive layer 9 contains the thermally conductive particles 9 and the soft magnetic particles 10, the thermally conductive particles 9 prevent the soft magnetic particles 10 from coming into contact with each other, whereby the eddy current caused by the contact of the soft magnetic particles 10 can be prevented, thereby suppressing The convergence of the flux is reduced. As a result, the magnetic shielding property can be more surely improved.

Further, in addition to the magnetic layer 4, the magnetic flux can be converged by the bonding layer 3. Therefore, the thickness of the magnetic layer 4 can be reduced, and the thickness of the coil module 6 can be reduced.

Further, since the heat generated by the current generated by the coil pattern 6 can be efficiently diffused to the periphery of the coil module 1 via the bonding layer 3, the expansion of the coil pattern 6 caused by heat can be suppressed, and even the coil pattern 6 can be suppressed. The inductance changes, so that the deterioration of communication characteristics can be suppressed.

In addition, since the magnetic layer 4 contains the soft magnetic particles 10 and the resin, the coil module 1 has flexibility and is excellent in handleability. Further, in the prior art method of using a sheet containing only a metal component such as a ferrite sheet, since the sheet is brittle, it is necessary to protect the support layer. However, since the coil module 1 has flexibility, the magnetic layer 4 has flexibility. There is no need to protect the support layer. Therefore, further thinning can be achieved.

Further, in the adhesive layer 3 and the magnetic layer 4, the soft magnetic particles 10 are aligned in the plane direction as shown in Fig. 1 . Therefore, the adhesive layer 3 and the magnetic layer 4 can exhibit excellent magnetic properties, and the magnetic shielding property is improved, and further thinning can be achieved.

The coil module 1 can be used for a wireless communication or wireless power transmission coil module using a frequency band of 13.56 MHz or 6.78 MHz, and is preferably used as a receiving coil module for NFC (Near Field Communication). Specific examples of the wireless communication use include a non-contact type IC card and a smart phone. Examples of the wireless power transmission use include a wireless telephone and an electric shaver. Electric toothbrushes, etc.

[Examples]

Hereinafter, the present invention will be specifically described by showing examples and comparative examples, but the present invention is not limited to the examples and comparative examples. The specific values such as the blending ratio (content ratio), the physical property value, and the parameters used in the following descriptions may be replaced by the blending ratios (content ratios), physical property values, and parameters described in the above-mentioned "embodiments". The corresponding upper limit (the value defined in the form of "below" or "not reached") or the lower limit (the value defined in the form of "above" or "exceed").

Example 1

(Preparation of magnetic layer)

In the case where the volume ratio of the soft magnetic particles in the magnetic composition is 60.0% by volume, 90.3 parts by mass of the Fe-Si-Al alloy (soft magnetic particles) in terms of solid content, and a cresol novolac type epoxy resin. 2.5 parts by mass, phenol-stretched benzene resin 2.6 parts by mass, C 4.2 parts by mass of the olefinic resin, 0.1 part by mass of the thermosetting catalyst, 0.1 part by mass of the dispersing agent, and 0.2 part by mass of the rheology controlling agent were mixed, whereby a magnetic composition was obtained.

A magnetic composition solution having a solid content concentration of 41% by mass was prepared by dissolving the magnetic composition in methyl ethyl ketone.

The magnetic composition solution was applied onto a separator (PET film subjected to polyoxynitridation treatment), followed by drying at 110 ° C for 2 minutes. Thereby, a semi-hardened magnetic layer (average thickness 20 μm) was formed.

The five layers of the semi-hardened magnetic layer were laminated, and heat-hardened by hot pressing at 175 ° C, 30 minutes, and 20 MPa. Thereby, a magnetic layer (average thickness 100 μm) in a completely hardened state (C stage) was obtained.

(formation of laminated body)

The amount of the thermal conductive particles in the composition was 30.0% by volume and the volume ratio of the soft magnetic particles was 10.0% by volume, and 47.2 parts by mass of alumina (thermally conductive particles) in terms of solid content, Fe- 26.8 parts by mass of Si-Al alloy (soft magnetic particles), 4.8 parts by mass of bisphenol A type epoxy resin, 1.8 parts by mass of cresol novolac type epoxy resin, 7.3 parts by mass of phenol-stretched benzene resin, and acrylic resin 11.8 The parts by mass and 0.3 parts by mass of the thermosetting catalyst were mixed, whereby the following composition was obtained.

A composition solution of a composition having a solid content concentration of 45% by mass was prepared by dissolving the subsequent composition in methyl ethyl ketone.

The subsequent composition solution was applied onto a separator (PET film subjected to polyfluorene stripping treatment), followed by drying at 110 ° C for 2 minutes. Thereby, a semi-hardened adhesive layer (average thickness 20 μm) was produced.

The semi-hardened layer of the second layer was prepared, and the two layers were semi-hardened and then laminated on the upper surface of the magnetic layer, and pressurized at 100 ° C, 1 minute, and 1 MPa. Thereby, a semi-hardened layered layered body having a semi-hardened back layer (average thickness of 40 μm) provided on the upper surface of the magnetic layer was obtained.

(Manufacture of coil module)

A coil substrate having a rectangular loop coil formed on a surface of a base substrate (polyimide made of polyimide, thickness: 20 μm) was prepared.

The width of the wiring of the loop coil was 1000 μm, the height Y of the wiring was 20 μm, and the interval X (pitch) between the wirings was 500 μm.

The semi-hardened layered laminate was laminated on the coil substrate in such a manner that the semi-hardened layer was in contact with the coil pattern, and hot pressed at 175 ° C, 30 minutes, and 1 MPa. Thereby, the coil pattern is buried in the semi-hardened back layer, and the semi-hardened back layer is completely cured, thereby manufacturing a coil module including a coil substrate, an adhesive layer, and a magnetic layer in this order (see FIG. 1).

In the coil module, the maximum thickness X of the subsequent layer was 35 μm, and the interval Z between the upper surface of the coil pattern and the upper surface of the layer 3 was 20 μm.

Example 2

The composition was then changed to the formulation of Table 1 and the blending ratio. Further, in order to set the maximum thickness X and the interval Z of the adhesive layer to the same distance as in the first embodiment, the pressing pressure at the time of forming the laminated body and the pressing pressure at the time of manufacturing the coil module are changed from 1 MPa. It is 2 MPa. The coil module of Example 2 was fabricated in the same manner as in Example 1 except for the above changes.

Example 3

The composition was then changed to the formulation of Table 1 and the blending ratio. Further, in order to set the maximum thickness X and the interval Z of the adhesive layer to the same distance as in the first embodiment, the pressing pressure at the time of forming the laminated body and the pressing pressure at the time of manufacturing the coil module are changed from 1 MPa. It is 4 MPa. The coil module of Example 3 was produced in the same manner as in Example 1 except for the above changes.

Comparative example 1

The composition was then changed to the formulation of Table 1 and the blending ratio. Furthermore, in order to follow The maximum thickness X and the interval Z of the layer were set to the same distance as in the first embodiment, and the pressurizing pressure at the time of formation of the laminated body and the pressurizing pressure at the time of manufacture of the coil module were changed from 1 MPa to 0.1 MPa. A coil module of Comparative Example 1 was produced in the same manner as in Example 1 except for the above changes.

Comparative example 2

The composition was then changed to the formulation of Table 1 and the blending ratio. Further, in order to set the maximum thickness X and the interval Z of the adhesive layer to the same distance as in the first embodiment, the pressing pressure at the time of forming the laminated body and the pressing pressure at the time of manufacturing the coil module are changed from 1 MPa. It is 5 MPa. A coil module of Comparative Example 2 was produced in the same manner as in Example 1 except for the above changes.

(the thermal conductivity of the layer)

The thermal conductivity in the plane direction in the subsequent layer was determined according to the following formula. The results are shown in Table 1.

(thermal conductivity) = (thermal diffusion coefficient) × (specific heat) × (specific gravity)

Further, the thermal diffusivity was measured using a xenon flash thermal method (manufactured by NETZSCH Japan Co., Ltd., LFA447 nanoflash). The specific heat system was obtained by DSC (manufactured by TA Instruments, Q-2000) by a measurement method according to JIS-7123. The specific gravity was measured using an electronic hydrometer (manufactured by Alfa Mirage, "MDS-300").

(adhesive)

In the coil modules of the respective examples and the comparative examples, the magnetic layer was peeled off from the coil substrate.

At this time, the case where the peeling state in the adhesive layer was agglomerated and peeled off was evaluated as ○, the case where the agglomerated fracture and the interface peeling were mixed was evaluated as Δ, and the case where the interface was peeled off was evaluated as ×. The results are shown in Table 1.

(magnetic properties)

For the adhesion layers in the coil modules of the respective embodiments and the comparative examples, impedance division is used. The separator ("4294A" manufactured by Agilent Co., Ltd.) was measured for the real part μ' of the complex magnetic permeability by a single coil method (frequency 13.56 MHz). The results are shown in Table 1.

Further, the magnetic layer was also measured in the same manner, and as a result, the real part μ' of the complex magnetic permeability of the magnetic layer was all 100.

(magnetic shielding)

The coil module 1 of each of the embodiments and the comparative examples is placed on the upper surface of the mounting table 15 so that the magnetic field probe 16 is positioned across the coil module 1 at a height of 5 mm from the upper surface of the mounting table 15. Move in the horizontal direction (refer to Figure 3). Further, MP-10L manufactured by NEC Engineering Co., Ltd. was used as a magnetic field probe, and the current applied to the coil was set to 40 mA and 13.56 MHz. The magnetic field strength at this time is measured by a magnetic field probe.

Further, a coil module including a coil substrate not including the adhesive layer and the magnetic layer was used as a reference, and the magnetic field strength was also measured for the reference coil module in the same manner as described above.

For the coil modules of the respective embodiments and the comparative examples, the case where the magnetic field strength of the coil module of the reference is reduced by 2dBuA/m or more is evaluated as ◎, which is reduced by 1dBuA/m or more and less than 2dBuA/ The case of the magnetic field strength of m was evaluated as ○, and the case where the magnetic field strength of less than 1 dRuA/m was lowered was evaluated as ×. The results are shown in Table 1.

(communication characteristics)

The communication characteristics of the coil modules of the respective examples and comparative examples were evaluated in the following manner. In other words, in the same manner as the heat dissipation evaluation, the coil patterns of the coil modules of the respective examples and the comparative examples were energized, and the change in inductance accompanying the temperature change was observed.

In the case of the inductance change in the case of Comparative Example 2, the case where the inductance change was small was evaluated as ○, and the case where the inductance change was large was evaluated as ×. The results are shown in Table 1.

The values in the various components in the table represent the solid components. Further, unless otherwise stated, the numerical values in the respective components in the tables represent parts by mass. The details of each of the components in the examples and tables are described below.

. Fe-Si-Al alloy, soft magnetic particles, flat shape, manufactured by Shanyang Special Steel Co., Ltd.

. Alumina: Al ₂ O ₃ , thermally conductive particles, spherical, average particle size 3 μm, manufactured by Admatechs

. Boron nitride: BN, thermal conductive particles, flat, average particle size 46 μm, manufactured by Electric Chemical Industry Co., Ltd.

. Fused yttrium oxide: spherical, average particle size 5 μm, manufactured by Electric Chemical Industry Co., Ltd.

. Cresol novolak type epoxy resin: the epoxy resin of the above structural formula (1), epoxy equivalent 199g / eq., ICI viscosity (150 ° C) 0.4Pa. s, the trade name "KI-3000-4", manufactured by Dongdu Chemical Co., Ltd.

. Bisphenol A type epoxy resin: epoxy resin of the above structural formula (2), epoxy equivalent 180g/eq., ICI viscosity (150 ° C) 0.05Pa. s, the trade name "Epikote YL980", manufactured by Mitsubishi Chemical Corporation

. Phenol-coupling benzene resin: the phenolic resin of the above structural formula (3), hydroxyl equivalent weight 203g / eq., ICI viscosity (150 ° C) 0.05Pa. s, the trade name "MEH-7851SS", manufactured by Minghe Chemical Co., Ltd.

. Acrylic resin: ethyl acrylate-butyl acrylate-acrylonitrile copolymer modified with carboxyl group and hydroxyl group, weight average molecular weight 900,000, trade name "Teisan Resin SG-70L" (resin content ratio 12.5% by mass), Nagase chemteX Manufacturing

. Thermal curing catalyst: 2-phenyl-1H-imidazole 4,5-dimethanol, trade name "Curezol 2PHZ-PW", manufactured by Shikoku Chemicals Co., Ltd.

. Dispersant: polyether phosphate, acid value 17, trade name "HIPLAAD ED152", manufactured by Nanben Chemical Co., Ltd.

. Rheology control agent: urea modified medium polar polyamine, trade name "BYK430" (solid content 30% by mass), manufactured by BYK-Chemie Japan

Furthermore, the invention described above is provided as an exemplified embodiment of the invention, and is merely illustrative and not restrictive. Variations of the invention that are apparent to those skilled in the art are included in the scope of the following claims.

[Industrial availability]

The coil module of the present invention can be applied to various industrial products, and can be used for wireless communication applications such as non-contact type IC cards and smart phones; for example, wireless power transmission applications such as wireless phones, electric shavers, and electric toothbrushes.

1‧‧‧ coil module

2‧‧‧Coil substrate

3‧‧‧Next layer

4‧‧‧Magnetic layer

5‧‧‧Base resin

6‧‧‧ coil pattern

7‧‧‧Wiring

9‧‧‧thermal particles

10‧‧‧Soft magnetic particles

Z‧‧‧The distance between the upper surface of the coil pattern and the upper surface of the layer

Claims (3)

A coil module characterized in that it is a wireless communication or wireless power transmission user using a frequency band of 13.56 MHz or 6.78 MHz, and includes a coil substrate including a substrate and a thickness direction side of the substrate a coil pattern; an adhesive layer formed on one side in a thickness direction of the coil substrate and formed of a heat-conductive particle, a soft magnetic particle and a resin-attached composition; and a magnetic layer provided on a thickness of the adhesive layer One side of the direction is formed of a magnetic composition containing soft magnetic particles and a resin. The coil module according to claim 1, wherein a content ratio of the soft magnetic particles to 100 parts by mass of the thermally conductive particles is 50 parts by mass or more and 2000 parts by mass or less in the adhesive layer. A method for manufacturing a coil module, which is characterized in that it is a method for manufacturing a coil module for wireless communication or wireless power transmission using a frequency band of 13.56 MHz or 6.78 MHz, and includes the following steps: preparing a soft magnetic particle and a resin a step of forming a magnetic layer formed by the magnetic composition; and obtaining a semi-hardened layer by a semi-hardened adhesive layer formed of a subsequent composition comprising thermally conductive particles, soft magnetic particles and a thermosetting resin And a step of: thermally laminating the semi-hardened layered body with the coil substrate including the substrate and the coil pattern in such a manner that the semi-hardened back layer is in contact with the coil pattern, thereby obtaining a coil mold including a fully hardened back layer The steps of the group.