WO2011010697A1 - 電磁波シールドシート - Google Patents
電磁波シールドシート Download PDFInfo
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- WO2011010697A1 WO2011010697A1 PCT/JP2010/062359 JP2010062359W WO2011010697A1 WO 2011010697 A1 WO2011010697 A1 WO 2011010697A1 JP 2010062359 W JP2010062359 W JP 2010062359W WO 2011010697 A1 WO2011010697 A1 WO 2011010697A1
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- nonwoven fabric
- metal
- electromagnetic wave
- wave shielding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K9/00—Screening of apparatus or components against electric or magnetic fields
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/06—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/83—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with metals; with metal-generating compounds, e.g. metal carbonyls; Reduction of metal compounds on textiles
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M17/00—Producing multi-layer textile fabrics
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K9/00—Screening of apparatus or components against electric or magnetic fields
- H05K9/0073—Shielding materials
- H05K9/0081—Electromagnetic shielding materials, e.g. EMI, RFI shielding
- H05K9/0084—Electromagnetic shielding materials, e.g. EMI, RFI shielding comprising a single continuous metallic layer on an electrically insulating supporting structure, e.g. metal foil, film, plating coating, electro-deposition, vapour-deposition
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/02—2 layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/03—3 layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/20—All layers being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/20—Inorganic coating
- B32B2255/205—Metallic coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
- B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/20—Fibres of continuous length in the form of a non-woven mat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/22—Fibres of short length
- B32B2305/28—Fibres of short length in the form of a mat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
- B32B2307/202—Conductive
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/16—Synthetic fibres, other than mineral fibres
- D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M2101/32—Polyesters
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/654—Including a free metal or alloy constituent
- Y10T442/657—Vapor, chemical, or spray deposited metal layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
Definitions
- the present invention relates to an electromagnetic wave shielding sheet having good electromagnetic wave shielding characteristics and capable of being thinned.
- the electromagnetic shielding material is required to have high electromagnetic shielding (electromagnetic shielding characteristics), and at the same time, a material having flexibility, bending resistance, thinness, and lightness is desired.
- Patent Document 1 and Patent Document 2 by forming an electromagnetic shielding material by laminating woven fabrics, non-woven fabrics, or woven fabrics and non-woven fabrics, a metal film is formed as compared with conventional products. It is disclosed that the increase in the thickness of the fabric can be improved and the adhesion of the metal film and the plating processability can be improved. However, in this case, in order to obtain a desired electromagnetic wave shielding characteristic, there is a problem that the base material thickness after the metal film molding becomes large and the metal film itself becomes thick.
- Patent Document 3 discloses a technique for coating a surface of a fabric with a resin layer containing metal particles.
- metal particles are coated together with a resin, and the obtained sheet is rich in flexibility and flexible. Therefore, the technique described in Patent Document 3 seems to have been intended to be easy to use when actually using the electromagnetic shielding sheet.
- the high electrical conductivity of the metal is worsened by resin coating, and as a result, the electromagnetic wave shielding property is not high and the sheet is thick.
- Patent Documents 4 and 5 disclose that ultrafine fibers are used, metal processing is performed on the fiber surface, and the electromagnetic wave shielding property is enhanced by utilizing a high specific surface area.
- the fiber sheets disclosed in these documents although ultrafine fibers are used and the sheets are high in performance, the ultrafine fiber sheets are not practically usable because the strength of the sheets is weak. .
- Electrolytic plating is used, but in this process, the electrochemical reaction of plating is repeated for several layers, and repeated exposure to a drying or plating bath is repeated many times. For this reason, in these processes, the cloth itself was cut or a defect was formed on the cloth, and uniform processing could not be performed. Further, in the method of depositing metal, it is necessary to deposit the metal in a vacuum chamber, but at this time, the cloth does not have enough strength, or the cloth has a defect. Further, in order to firmly adhere to the fiber surface, it is necessary to make a high vacuum and to activate the fiber surface, and the fiber fabric could not withstand these processes.
- the problem to be solved by the present invention is to provide an electromagnetic wave shielding sheet having an excellent electromagnetic wave shielding property with a small amount of metal adhesion, with less increase in the thickness of the base material after the metal film is formed, as compared with the conventional electromagnetic wave shielding sheet. It is.
- the problem to be solved by the present invention is to provide a sheet that can withstand a metal working process, and as a result, has a thin and flexible fabric and has high electromagnetic shielding properties. But there is.
- the inventors have arranged a specific amount of ultrafine fiber layer as the middle layer of the laminated nonwoven fabric to optimize the denseness, and preferentially use metal in the ultrafine fiber layer. As a result, it was found that an electromagnetic wave shielding sheet that is thin and excellent in shielding properties can be obtained by adhering to the film, and the present invention has been completed.
- An electromagnetic wave shielding sheet comprising a laminated nonwoven fabric having at least a first layer and a second layer, wherein the first layer is a layer of thermoplastic synthetic fiber having a fiber diameter of 6 to 50 ⁇ m, and the second layer Is a layer of ultrafine fibers having a fiber diameter of 0.1 to 5.0 ⁇ m, and a metal is attached to at least one side of the sheet.
- the electromagnetic wave shielding sheet of the present invention has a small increase in the thickness of the substrate after the formation of the metal film, improves the adhesion of the metal film by arranging ultrafine fibers in the middle layer, reduces the amount of metal adhesion, and a small amount Even if it is metal-attached, it exhibits an excellent shielding property that the electromagnetic wave shielding property is 60 dB or more. Further, since the electromagnetic wave shielding sheet of the present invention is strong, the electromagnetic wave shielding sheet is thinner, lighter, and has a high performance, and can be embedded with high degree of freedom in highly integrated electronic devices. .
- the present invention comprises a laminated nonwoven fabric having at least a first layer and a second layer, wherein the first layer is a layer of thermoplastic synthetic fiber having a fiber diameter of 6 to 50 ⁇ m, and the second layer has a fiber diameter of 0.00.
- An electromagnetic wave shielding sheet comprising a layer of 1 to 5.0 ⁇ m ultrafine fibers, wherein a metal is attached to at least one surface of the sheet.
- the electromagnetic wave shielding sheet of this invention can also be a sheet
- the structural features of the electromagnetic wave shielding sheet of the present invention and the effects exerted thereby are as follows: (1)
- the sheet of the present invention has a structure in which a large fiber gap formed by a thermoplastic synthetic fiber layer having a relatively large fiber diameter is filled with a layer of ultrafine fibers having a relatively small fiber diameter.
- the surface exposure of the ultrafine fiber layer is high. For this reason, metal can be preferentially adhered to the ultrafine fiber layer, and as a result, the effective surface area of the metal can be significantly increased, and an excellent shielding effect can be expressed with a small amount of adhesion. It is done.
- the sheet of the present invention preferably has a laminated nonwoven fabric structure in which the middle layer is an ultrafine fiber layer.
- the ultrafine fiber layer acts as an adhesive layer, and the entire sheet is densified. As a result, it is considered that a thin sheet and a flexible sheet can be obtained.
- thermoplastic synthetic fiber used for the first layer and / or the third layer of the laminated nonwoven fabric of the present invention can be determined as appropriate depending on the use environment and processing conditions.
- Polyethylene terephthalate, polybutylene terephthalate, copolymer polyester Polyester fibers such as nylon 6, nylon 66, polyamide fibers such as copolymerized polyamide fibers, and crystalline engineering plastics such as PPS are preferable.
- the fiber used in the present invention is used as a base material for an electromagnetic wave shielding sheet, and can withstand metalworking processes, particularly wet plating processes, and can maintain high adhesion to metals. From the viewpoint of dimensional stability when wet, polyester fibers and PPS fibers are more preferable.
- the thermoplastic synthetic fiber used for the first layer and the third layer of the laminated nonwoven fabric has a fiber diameter of 6 to 50 ⁇ m, preferably 8 to 30 ⁇ m, more preferably 8 to 20 ⁇ m. If it is 6 micrometers or more, the intensity
- the thermoplastic synthetic fiber layer having a relatively large fiber diameter has a relatively large fiber gap, and the size of the fiber gap is preferably 30 to 10,000 ⁇ m as the pore diameter.
- the thickness is preferably 50 to 1000 ⁇ m, more preferably 50 to 300 ⁇ m.
- the material of the ultrafine fiber used for the second layer of the laminated nonwoven fabric of the present invention can be appropriately determined depending on the use environment and processing conditions. Moreover, the same thing as the thermoplastic synthetic fiber used for the 1st layer and / or 3rd layer of a laminated nonwoven fabric may be different.
- polyester fibers such as polyethylene terephthalate, polybutylene terephthalate and copolymerized polyester, polyamide fibers such as nylon 6, nylon 66 and copolymerized polyamide fibers, and crystalline engineering plastics such as PPS are preferable.
- the ultra-fine fiber used in the present invention is used for a laminated nonwoven fabric used as a base material for an electromagnetic wave shielding sheet, and for the same reason as the resin used for the first layer and the third layer, and more strongly metal From the viewpoint that the layer needs to be fixed, polyester fibers and PPS fibers are preferable.
- the ultrafine fiber layer which is the second layer, is arranged so as to fill such a fiber gap.
- the metal can preferentially adhere to the ultrafine fiber layer.
- FIG. 1 is a schematic plan view showing a surface state of an ultrafine fiber
- FIG. 2 is a schematic cross-sectional view showing a cross-sectional state.
- the exposed area ratio in the surface of the ultrafine fiber layer is preferably 20% or more, more preferably 50 to 90%, and further preferably 60 to 80%. Depending on the exposed area ratio, metal is attached to the ultrafine fiber layer. For this reason, a metal becomes a continuous layer and can exhibit a higher shielding effect.
- a polyester fiber layer having an upper layer lower layer fiber diameter of 13 ⁇ m it has a fiber gap with a diameter of 120 ⁇ m, and the gap is an ultrafine fiber layer with a fine fiber diameter. It is completely filled.
- the fiber diameter of the ultrafine fibers constituting the second layer is 0.1 to 5.0 ⁇ m, preferably 0.4 to 3.0 ⁇ m.
- the specific surface area of the ultrafine fiber layer is increased, and the distance between the ultrafine fibers is reduced, so that a favorable metal coating layer can be formed.
- the thickness is 0.1 ⁇ m or more, a high-quality fiber / sheet is produced in producing the fiber. If it is less than 0.1 ⁇ m, the ultrafine fibers may be entangled with each other, or if they are heat-melting fibers, they will be fused together, and if they are made into a sheet, there is a possibility that it will become a thread trap or a defect.
- the ultrafine fiber is 5.0 ⁇ m or less, the specific surface area becomes large, and the amount of fiber per unit volume / area increases. Therefore, when metal processing is performed, a more continuous metal film is formed, and electromagnetic waves are formed. Shielding is improved. In the same sense, the distance between the fibers is narrowed, a more continuous metal film is formed, and the electromagnetic wave shielding property is enhanced.
- the thickness of the laminated nonwoven fabric is preferably 10 ⁇ m to 100 ⁇ m, more preferably 10 to 60 ⁇ m, and still more preferably 10 to 40 ⁇ m.
- the electromagnetic wave shielding sheet of the present invention is not bulky and can be installed even in a small space by setting the nonwoven fabric to such a thickness. If the thickness is 10 ⁇ m or more, the laminated nonwoven fabric is strong and has sufficient strength by metal processing, and an electromagnetic wave shielding sheet can be obtained efficiently. On the other hand, if it is 100 ⁇ m or less, it is thinner, more flexible and easy to use.
- the first layer mainly governing the strength of the fabric and the second layer mainly governing the shielding performance because of having a large specific surface area when the metal is processed, that is, a layer having a different role. Since it is a sheet, it becomes a thin, flexible, and high-performance electromagnetic shielding sheet.
- the basis weight of each layer (first layer, second layer, and / or third layer) of the laminated nonwoven fabric is preferably a value described below depending on the ratio of each layer.
- the basis weight of the ultrafine fiber nonwoven fabric layer forming the second layer in the present invention is preferably 0.5 g / m 2 or more. If it is 0.5 g / m 2 or more, the distance between fibers does not become too large, and the metal to be processed can easily enter the gap, and a uniform and dense continuous metal layer can be formed. In this sense, the basis weight of the ultrafine fiber nonwoven fabric layer forming the second layer is more preferably 1.5 g / m 2 or more.
- the basis weight of the nonwoven fabric layer made of the thermoplastic resin forming the first layer (and / or the third layer) is preferably 5 g / m 2 or more, and more preferably 7 g / m 2 or more. If it is 5 g / m 2 or more, a sufficiently uniform inter-fiber distance can be obtained as a laminated nonwoven fabric, so that a dense and uniform continuous metal layer can be formed.
- the ultrafine fiber layer forming the second layer is more uniformly arranged between the fibers forming the first layer, and as a result, the ultrafine fibers are more uniformly distributed as a laminated nonwoven fabric. As a result, a dense and uniform continuous metal layer can be formed through the ultrafine fiber layer distributed more uniformly.
- the content of the ultrafine fibers with respect to the whole nonwoven fabric is preferably 12 to 23 wt%, more preferably 16 to 23 wt%. More preferably, it is 16 to 20 wt%.
- the ultrafine fiber is 12 wt% or more, the specific surface area is high and the inter-fiber distance is stable.
- the ultrafine fiber is 23 wt% or less, the fabric tension of the first thermoplastic polymer layer is high and the surface is fluff resistant. Will also be good. In any case, it is important to ensure the necessary thickness and basis weight, and should be appropriately selected within the range.
- the bulk density of the laminated nonwoven fabric is preferably 0.3 to 0.8 g / cm 3 , more preferably 0.4 to 0.7 g / cm 3 , and still more preferably 0.5 to 0.7 g / cm 3. cm 3 .
- the cloth strength is excellent, the distance between the fibers is not too far away, and when the metal is processed, the metal tends to become a continuous layer, and a higher performance electromagnetic shielding property.
- it is 0.8 g / cm 3 or less, it is light and has good liquid permeability of electroless plating, and it is good because air permeability and liquid permeability remain in the original meaning of a nonwoven fabric material.
- a metal layer may be provided on the film or sheet, or the metal foil itself may be used.
- Nonwoven fabrics are composed of fibers and void layers that are the gaps between them, but the shape of the void layer is generally random.
- the average pore size distribution exceeds 30 ⁇ m.
- the maximum pore diameter exceeds 50 ⁇ m. That is, voids having an approximate diameter of 50 ⁇ m or more are included in the nonwoven fabric.
- the metal to be processed does not enter the hole portion, a continuous metal layer cannot be formed, and electromagnetic wave leakage tends to occur.
- the ultrafine fiber layer by having the ultrafine fiber layer, the distance between the fibers is reduced, that is, the pore diameter is reduced, and a uniform continuous metal layer is easily formed.
- the average pore diameter of the laminated nonwoven fabric of the present invention is preferably 0.3 ⁇ m or more and 20 ⁇ m or less. If it is 0.3 micrometer or more, the metal to process is easy to enter and it can implement
- the distance is 20 ⁇ m or less, the distance between fibers is moderate, the metal to be processed and the electrolytic solution used for electroless plating can easily enter, and as a result, a good continuous metal layer can be formed, and high-performance electromagnetic shielding properties Can be realized.
- the tensile strength of the laminated nonwoven fabric is desirably 20 N / 3 cm or more. If it is 20 N or more, the electromagnetic wave shielding sheet can be produced more efficiently without the laminated sheet being cut or wrinkled in the steps of electroless plating, vacuum deposition, and sputtering.
- the laminated nonwoven fabric is calendered.
- the ultrafine fibers that make up the middle layer of the laminated nonwoven fabric serve as an adhesive by calendering and prevent the occurrence of delamination of the laminated nonwoven fabric, so that it is possible to obtain a laminated nonwoven fabric with higher strength and better dimensional stability. it can.
- the tensile strength of the laminated nonwoven fabric is more preferably 25 N / 3 cm or more.
- metal is attached to at least one side of the sheet.
- metal processing is performed on the side of the ultrafine fiber layer serving as the second layer.
- electroless plating As a method for attaching the metal, electroless plating, metal vapor deposition, and sputtering are preferable.
- electroless plating is more preferable in the sense that more metal layers can be more uniformly fixed. Since this sheet has good strength and dimensional stability and can withstand this electroless plating process, it can exhibit higher performance electromagnetic shielding.
- the metal used for the metal coating layer is not particularly limited.
- known materials such as copper, nickel, zinc, aluminum, tin, silver, gold, indium, chromium, platinum, iron, cobalt, molybdenum, titanium, palladium, SUS, and niobium can be used.
- the metal coating layer at least one kind of metal can be used.
- an industrially preferable aspect is preferably nickel, copper, silver, gold, or the like in consideration of material cost, process loss, and conductivity deterioration due to oxidation.
- a preferable range of the metal adhesion amount is 2 to 50 g / m 2 , and more preferably 4 to 35 g / m 2 .
- the present invention it is not unconditionally defined because it depends on the fiber structure of the laminated nonwoven fabric, but it is preferable that 20 wt% or more of the metal is attached to the ultrafine fibers, more preferably 30 to 90 wt%, More preferably, it is 50 to 90 wt%.
- 20 wt% or more of the metal adheres to the ultrafine fibers, it becomes easy to form a continuous metal layer, so that the shielding characteristics are improved.
- the surface resistivity of the electromagnetic wave shielding sheet of the present invention varies depending on the degree of entanglement between the fibers of the laminated nonwoven fabric, the metal species fixed to the surface of the fabric, and the amount, but in order to obtain more reliable shielding performance
- the common logarithm of the rate is preferably in the range of -2.0 to -0.2 ⁇ / ⁇ , more preferably -1.8 to -0.6 ⁇ / ⁇ , and still more preferably -1.8 to -0.8 ⁇ . / ⁇ , most preferably ⁇ 1.8 to ⁇ 1.0 ⁇ / ⁇ .
- the common logarithmic value of the surface resistivity is ⁇ 0.2 ⁇ / ⁇ or less, and it has good electromagnetic shielding properties.
- the common logarithm value of the surface resistivity exceeds ⁇ 0.2 ⁇ / ⁇ , the metal film is not uniform and it is difficult to obtain high electromagnetic shielding properties.
- the electromagnetic wave shielding sheet of the present invention preferably has an electromagnetic wave shielding property of 43 dB or more, more preferably 53 dB or more, still more preferably 60 dB or more, and most preferably 70 dB or more.
- an electromagnetic wave shield it is generally said that the shield characteristic is 43 dB or more, and it is said that it is at a practical level, and by clearing this value, practically usable applications are expanded. In any case, this value varies depending on the structure and thickness of the laminated nonwoven fabric and the type and amount of metal to be processed.
- the present invention obtains these high-performance electromagnetic shielding properties, and is further characterized by being a thin, light and flexible material.
- the electromagnetic wave shielding sheet of the present invention is composed of a laminated nonwoven fabric composed of an extra fine fiber nonwoven fabric layer and a nonwoven fabric layer.
- the method of laminating the ultrafine fiber nonwoven fabric layer and the nonwoven fabric layer is made of thermoplastic resin for both the nonwoven fabric layer and the ultrafine fiber nonwoven fabric layer. Therefore, the method of integrating with hot embossing maintains the tensile strength and bending flexibility of the nonwoven fabric, and is heat resistant. It is preferable because stability can be maintained.
- Preferred is a method in which a spunbonded nonwoven fabric layer, a meltblown nonwoven fabric layer, and a spunbonded nonwoven fabric layer are sequentially produced and laminated and pressure-bonded with an embossing roll or a hot press roll.
- At least one spunbonded nonwoven fabric layer is spun on a conveyor using a thermoplastic synthetic resin, and an ultrafine fiber having a fiber diameter of 0.1 to 5 ⁇ m is formed thereon by a melt-blown method using a thermoplastic synthetic resin.
- Spray at least one non-woven fabric layer is preferable.
- at least one thermoplastic synthetic long-fiber nonwoven fabric using a thermoplastic synthetic resin is laminated on the meltblown nonwoven fabric, and then integrated by crimping using an emboss roll or flat roll. The method is more preferred.
- the ultrafine fiber nonwoven fabric layer by the melt-blown method is directly sprayed on the thermoplastic synthetic long-fiber nonwoven fabric layer, so that the ultrafine fiber by the melt-blown method penetrates into the thermoplastic synthetic long-fiber nonwoven fabric layer.
- the fiber gap of the thermoplastic synthetic long fiber nonwoven fabric layer can be filled.
- Weight per unit area (g / m 2 ): The weight of a sample 24 cm ⁇ 33 cm was converted to 1 m 2 .
- Thickness According to the method defined in JIS L-1906, the thickness was measured at 10 locations per 1 m width, and the average value was obtained. The load was 9.8 kPa.
- Average fiber diameter A 500 times magnified photograph was taken with an electron microscope, and the average value of 10 fibers was obtained.
- Tensile strength of nonwoven fabric Take test pieces with a width of 30mm and a length of about 250mm per 1m in the width direction, and take tensile strength and breaking elongation at a grasping interval of 100mm and a tensile speed of 300mm / min. The average value was measured.
- Opening Diameter Distribution A palm porometer (model: CFP-1200AEX) manufactured by PMI was used.
- SMIWICK made by PMI was used as the immersion liquid, and the sample was immersed in the immersion liquid and sufficiently deaerated to measure.
- the filter is immersed in a liquid with a known surface tension in advance, and pressure is applied to the filter from a state in which all pores of the filter are covered with a liquid film. The pore diameter calculated from the tension is measured. The following formula (3) is used for the calculation.
- d C ⁇ ⁇ / P Formula (3)
- d (unit: ⁇ m) is the pore diameter of the filter
- ⁇ (unit: mN / m) is the surface tension of the liquid
- P (unit: Pa) is the pressure at which the liquid film of the pore diameter is broken
- C is a constant. is there. From Equation (3), when the flow rate (wetting flow rate) when the pressure P applied to the filter immersed in the liquid is continuously changed from low pressure to high pressure is measured, the initial pressure is broken even with the liquid film with the largest pores. The flow rate is zero. As the pressure is increased, the liquid film with the largest pores is destroyed and a flow rate is generated (bubble point).
- the cumulative filter flow rate (unit:%).
- the pore size of the liquid film that is broken at a pressure at which the cumulative filter flow rate is 50% is referred to as the average flow pore size.
- the maximum pore size was set to the range of ⁇ 2 ⁇ in which the cumulative filter flow rate was 50%, that is, the pore size of the liquid film that was broken at a pressure at which the cumulative filter flow rate was 2.3%.
- Ventilation resistance (kPa ⁇ s / m) Using a KES-F8-AP1 ventilation resistance tester manufactured by Kato Tech Co., Ltd., from the differential pressure at an air permeability of 4 cm 3 / cm 2 ⁇ s, the ventilation resistance (kPa ⁇ s / m) m) was measured.
- Metal adhesion amount (g / m 2 ): A value obtained by subtracting the original fabric weight before processing from the basis weight after metal adhesion processing.
- Electromagnetic shielding characteristics (dB) Electric field shielding characteristics dB (near field shielding characteristics) at 100 MHz and 1 GHz were evaluated by the KEC method.
- a general-purpose polyethylene terephthalate is extruded by spunbonding at a spinning temperature of 300 ° C. and a filament group of filaments is extruded toward the moving collection surface, and is spun at a spinning speed of 3500 m / min.
- polyethylene terephthalate (melt viscosity ⁇ sp / c 0.50) was spun by a melt blown method under the conditions of a spinning temperature of 300 ° C., a heating air temperature of 320 ° C., and a discharge air of 1000 Nm 3 / hr / m.
- Ultrafine fibers having a fiber diameter of 1.6 ⁇ m were directly ejected toward the long-fiber web formed as a random web having a basis weight of 5 g / m 2 (ultrafine fiber layer B).
- the distance from the meltblown nozzle to the upper surface of the long fiber web was set to 100 mm, and the suction on the collecting surface immediately below the meltblown nozzle was set to 0.2 kPa and the wind speed was about 7 m / sec.
- the laminated web was passed between a flat and a flat roll and thermocompression bonded to obtain a laminated nonwoven fabric.
- a polyethylene terephthalate long fiber web was opened in the same manner as the first prepared nonwoven fabric layer (nonwoven fabric layer A) before thermocompression bonding, and a three-layer laminated web consisting of A / B / A was prepared directly.
- the laminated web was passed between a flat and a flat roll and thermocompression bonded to obtain a laminated nonwoven fabric.
- the laminated nonwoven fabric was immersed in an aqueous solution containing palladium chloride 0.3 g / L, cuprous chloride 30 g / L, 36% hydrochloric acid 300 ml / L for 2 minutes, and the fiber surface of the laminated nonwoven fabric was washed. Subsequently, the substrate was immersed in borohydrofluoric acid having an acid concentration of 0.1 N so as to be maintained at 40 ° C. for 5 minutes, and then washed with water. Next, it was immersed in an electroless copper plating solution consisting of copper sulfate 7.5 g / L, 37% formalin 30 ml / L, and Rochelle salt 85 g / L at 40 ° C.
- Table 1 below shows the fiber diameters of the first layer, the second layer, and the third layer of the laminated nonwoven fabric of polyester fibers obtained by the above method, and the basis material configuration of the basis weight.
- the electromagnetic wave shielding sheet obtained in the above production example had good metal adhesion, the increase in thickness after metal processing was as small as 3 ⁇ m, and exhibited high shielding properties.
- the evaluation results are also shown in Table 1 below.
- the obtained electromagnetic wave shielding sheet had a very thin and high shielding property (65 dB) of 30 ⁇ m after metal processing.
- Example 2 A laminated nonwoven fabric of polyester fibers obtained in the same manner as in Example 1 was processed by a sputtering method to obtain an electromagnetic wave shielding sheet.
- Sputtering was performed using a vacuum deposition apparatus and a Nilaco standard board (model: SF-106 tungsten) as a heat source.
- the basic conditions were a degree of vacuum of 5 ⁇ 10 ⁇ 5 torr, an applied voltage of 5 V, and a deposition time of 180 seconds.
- the obtained electromagnetic wave shielding sheet was able to form a uniform metal film on the surface of the fiber without any back-through of the metal due to the ultrafine fibers used in the laminated nonwoven fabric.
- the evaluation results are shown in Table 1 below.
- Example 3 In the same manner as in Example 1, the spinning diameter, spinning temperature, spinning speed, suction force, and wind speed were changed to obtain a 1 m wide laminated nonwoven fabric of polyester fibers. The properties of the obtained nonwoven fabric are shown in Table 1 below. Further, in the same manner as in Example 1, metal was processed by an electroless plating method to obtain an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are also shown in Table 1 below.
- Example 4 The same nonwoven fabric as in Example 3 was used, the electroless plating treatment time was shortened, the metal was processed into an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are shown in Table 1 below.
- Example 5 The same non-woven fabric as in Example 3 was used, the treatment time for electroless plating was increased, the metal was processed into an electromagnetic shielding sheet, and the properties and electromagnetic shielding characteristics were observed. The evaluation results are shown in Table 1 below.
- Example 6 to 10 Under the same conditions as in Example 3, a laminated nonwoven fabric in which the basis weight and thickness of the nonwoven fabric were changed was obtained. The properties of the resulting nonwoven fabric are shown in Table 1 below. Further, in the same manner as in Example 1, metal was processed by an electroless plating method to obtain an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are also shown in Table 1 below.
- Examples 11 and 12 Under the same conditions as in Example 3, a spunbond nonwoven fabric was obtained, and then the spinning diameter of the meltblown nonwoven fabric, and the spinning temperature, spinning speed, suction force, and wind speed were changed, and the fiber diameter of the meltblown nonwoven fabric was changed, Others were carried out similarly to Example 3, and obtained the laminated nonwoven fabric.
- the properties of the obtained nonwoven fabric are shown in Tables 1 and 2 below.
- metal was processed by an electroless plating method to obtain an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are also shown in Table 1 and Table 2 below.
- Example 13 and 14 The melt-blown nonwoven fabric is the same as in Example 3, and the spunbond nonwoven fabric spinning diameter, spinning temperature, and spinning speed are changed to change the fiber diameter of the spunbond nonwoven fabric. Got. The properties of the obtained nonwoven fabric are shown in Table 2 below. Further, in the same manner as in Example 1, metal was processed by an electroless plating method to obtain an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are also shown in Table 2 below.
- thermoplastic resin was PPS (Fortron manufactured by Polyplastics).
- Example 2 The conditions for producing the laminated nonwoven fabric and the performance thereof are shown in Table 2 below. Other conditions were the same as in Example 1 to obtain a laminated nonwoven fabric. The properties of the obtained nonwoven fabric are also shown in Table 2 below. Further, in the same manner as in Example 1, metal was processed by an electroless plating method to obtain an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are also shown in Table 2 below.
- Example 17 In the same method for producing a nonwoven fabric as in Example 3, the third layer was not overlapped, and other methods were carried out in the same manner as in Example 3 to obtain a two-layer type laminated nonwoven fabric (Example 17).
- the properties of the obtained nonwoven fabric are shown in Table 2 below.
- metal was processed by an electroless plating method to obtain an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are also shown in Table 2 below.
- the third layer was not overlapped, and other methods were carried out in the same manner as in Example 11 to obtain a two-layer type laminated nonwoven fabric (Example 18).
- Example 1 was subjected to metal processing by an electroless plating method to form an electromagnetic wave shielding sheet, and its properties and electromagnetic wave shielding characteristics were observed. The evaluation results are also shown in Table 2 below.
- Example 19 to 21 The same polyester fiber as in Example 3 and a 1 m wide laminated nonwoven fabric were subjected to metal processing of silver by the same sputtering method as in Example 2 to obtain an electromagnetic wave shielding sheet. I saw its properties and electromagnetic shielding properties. The evaluation results are shown in Table 2 below. Further, the sputtering time was adjusted to the metal processing amount shown in Table 2, and the electromagnetic wave shielding sheet, its properties and electromagnetic wave shielding characteristics were observed. The evaluation results are also shown in Table 2 below.
- Example 22 Aluminum was processed into a 1 m wide laminated nonwoven fabric of the same polyester fiber as in Example 3 by the same sputtering method as in Example 2 to obtain an electromagnetic wave shielding sheet.
- the amount of metal processing shown in Table 2 below was used as an electromagnetic shielding sheet, and the properties and electromagnetic shielding characteristics were observed. The evaluation results are also shown in Table 2 below.
- Example 23 The same two-layer laminated nonwoven fabric as in Example 17 was metal-processed into an electromagnetic wave shielding sheet by the same sputtering method as in Example 2, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are shown in Table 2 below.
- Example 1 A polyester fiber thermal bond single layer non-woven fabric (thickness 85 ⁇ m, bulk density 0.23 g / cm 3 ) was treated in the same manner as in Example 1, and an electromagnetic wave shielding sheet (metal adhesion amount 8 g / m 2 , surface resistivity ⁇ 0.66 ⁇ / ⁇ ) was obtained. As for workability, wrinkles frequently occurred on the way because the processed product was thick and the sheet was hard. In addition, the thickness after metal processing is 90 ⁇ m, which is inappropriate for use in miniaturized electronic devices. The evaluation results are shown in Table 3 below.
- Example 3 As the nonwoven fabric, a spunbond nonwoven fabric (E05025, basis weight 25 g / m 2 ) manufactured by Asahi Kasei Fiber was used. The composition and performance results of the nonwoven fabric are shown in Table 3 below. Next, in the same manner as in Example 1, electroless plating was performed and metal processing was performed to form an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. As for workability, wrinkles frequently occurred on the way because the processed product was thick and the sheet was hard. Further, the thickness after metal processing is about 120 ⁇ m, which is inappropriate for use in miniaturized electronic devices. The evaluation results are also shown in Table 3 below.
- Example 9 the same nonwoven fabric as Example 7 was fixed by fixed length and width, and the heat-set nonwoven fabric was obtained (comparative example 9).
- the plating time was set to the same time, and a prototype of 20 cm ⁇ 20 cm was obtained. These shield performances are shown in Table 3 below.
- Example 10 As the nonwoven fabric, the same laminated nonwoven fabric as in Example 3 was used, the plating time was shortened, a metal processed sheet having a desired metal processing amount was obtained, and the properties and electromagnetic shielding characteristics were observed. The evaluation results are shown in Table 3 below.
- Example 12 As the nonwoven fabric, a spunbond nonwoven fabric (E05025, basis weight 25 g / m 2 ) manufactured by Asahi Kasei Fiber was used. The composition and performance results of the nonwoven fabric are shown in Table 3 below. Next, silver was sputtered and metallized in the same manner as in Example 2 to obtain an electromagnetic wave shielding sheet, and the properties and electromagnetic wave shielding characteristics were observed. The evaluation results are shown in Table 3 below.
- Comparative Example 13 As the non-woven fabric, the same single-layer non-woven fabric as in Comparative Example 4 was used, and silver sputtering was performed in the same manner as in Example 2 to form an electromagnetic wave shielding sheet, and the properties and electromagnetic shielding characteristics were observed. The evaluation results are shown in Table 3 below.
- Example 16 the same nonwoven fabric as Example 7 was fixed by fixed length and width, and the heat-set nonwoven fabric was obtained (comparative example 16).
- metal processing was attempted by silver sputtering, but the nonwoven fabric was not thermally shrunk, but the nonwoven fabric was cut during processing, and a good continuous electromagnetic wave shielding sheet was obtained. It was not obtained.
- the laboratory without applying tension to the nonwoven fabric, only the plating time was set to the same time, and a prototype of 20 cm ⁇ 20 cm was obtained. These shield performances are shown in Table 3 below.
- Example 17 As the nonwoven fabric, the same laminated nonwoven fabric as in Example 3 was used, and the time was adjusted by the same silver sputtering method as in Example 2 to obtain a processed sheet with a small amount of metal processing, and the properties and electromagnetic shielding properties were observed. .
- the evaluation results are shown in Table 3 below.
- the electromagnetic wave shielding sheet of the present invention is an electromagnetic wave shielding sheet made of a non-woven fabric that exhibits a high shielding effect even with a small amount of metal adhesion. It can use suitably for an apparatus. Moreover, in the electromagnetic wave shielding sheet of the present invention, higher electromagnetic wave shielding properties can be obtained despite the thin thickness of the sheet, and the sheet is flexible and can be easily mounted on an electronic device or the like. Further, since the sheet strength is strong and the metal processed sheet can be obtained with higher efficiency, a high-performance electromagnetic shielding sheet is provided at low cost.
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Abstract
Description
[1]少なくとも第1層、及び第2層を有する積層不織布からなる電磁波シールドシートであって、該第1層は、繊維径6~50μmの熱可塑性合成繊維の層であり、該第2層は、繊維径0.1~5.0μmの極細繊維の層であり、そして該シートの少なくとも片面に金属が付着されていることを特徴とする前記シート。
本発明は、少なくとも第1層及び第2層を有する積層不織布からなり、該第1層は、繊維径6~50μmの熱可塑性合成繊維の層であり、該第2層は、繊維径0.1~5.0μmの極細繊維の層であることを特徴とするシートであって、そのシートの少なくとも片面に金属が付着されている電磁波シールドシートである。また、本発明の電磁波シールドシートは、前記積層不織布の第2層の上に、第1層を有したサンドイッチ構造の積層不織布からなるシートであることもできる。
(1)本発明のシートは、比較的繊維径の太い熱可塑性合成繊維の層により形成される大きな繊維間隙を、比較的繊維径の微細な極細繊維の層が埋め尽くす構造を有しており、極細繊維層の表面露出性が高い。このため極細繊維層に優先的に、金属を付着させることができ、その結果、金属の付着有効表面積を格段に大きくすることでき、少量の付着で優れたシールド効果を発現することができると考えられる。
(2)本発明のシートは、好ましくは中層が極細繊維層からなる積層不織布の構造を有する。極細繊維層は接着層として作用し、シート全体が緻密化される。その結果、薄地で、可撓性のあるシートが得られると考えられる。
本発明で第2層をなす極細繊維不織布層の目付は、0.5g/m2以上が好ましい。0.5g/m2以上であれば、繊維間距離が大きくなりすぎず、加工する金属が間隙に入り込み易く、均一で緻密な連続金属層を形成できる。この意味で、第2層をなす極細繊維不織布層の目付は、より好ましくは1.5g/m2以上である。
金属の付着方法としては、無電解メッキ、金属蒸着、スパッタリングが好ましい。また、より高性能の電磁波シールドシートとするには、金属層をより均一により多く固着することができる意味で、無電解メッキがより好ましい。本シートは、強度・寸法安定性がよいため、この無電解メッキ工程にも耐えられるため、より高性能の電磁波シールド性を発揮できる。
金属付着量の好ましい範囲は2~50g/m2であり、より好ましくは4~35g/m2である。
(3)平均繊維径(μm):電子顕微鏡で500倍の拡大写真をとり、10本の平均値で求めた。
PMI社のパームポロメーター(型式:CFP-1200AEX)を用いた。測定には浸液にPMI社製のシルウィックを用い、試料を浸液に浸して充分に脱気し、測定した。本測定装置は、フィルターを、あらかじめ表面張力が既知の液体に浸し、フィルターの全ての細孔を液体の膜で覆った状態からフィルターに圧力をかけ、液膜の破壊される圧力と液体の表面張力から計算された細孔の孔径を測定する。計算には下記の数式(3)を用いる。
d=C・γ/P 数式(3)
式中、d(単位:μm)はフィルターの孔径、γ(単位:mN/m)は液体の表面張力、P(単位:Pa)はその孔径の液膜が破壊される圧力、Cは定数である。
数式(3)より、液体に浸したフィルターにかける圧力Pを低圧から高圧に連続的に変化させた場合の流量(濡れ流量)を測定すると、初期の圧力は最も大きな細孔の液膜でも破壊されないので、流量は0である。圧力を上げていくと、最も大きな細孔の液膜が破壊され、流量が発生する(バブルポイント)。さらに圧力を上げていくと、各圧力に応じて流量は増加し、最も小さな細孔の液膜が破壊され、乾いた状態の流量(乾き流量)と一致する。本測定装置では、ある圧力における濡れ流量を、同圧力での乾き流量で割った値を累積フィルター流量(単位:%)と呼ぶ。累積フィルター流量が50%となる圧力で破壊される液膜の孔径を、平均流量孔径と呼ぶ。本発明での最大孔径は、累積フィルター流量が50%の-2σの範囲、すなわち、累積フィルター流量が2.3%となる圧力で破壊される液膜の孔径とした。
A:均一に金属被膜が形成されている
B:一部金属被膜が不均一で、場所により斑がある
C:金属被膜が不均一である
連続的に工程を通したときに、その加工性を以下の評価基準で判定した:
A:非常に良好
B:ほぼ良好
C:不良
とし、不良の場合は、その原因を実施例中に記した。
得られた試料に粘着テープを貼付し、その後、テープを剥がし、その固着状態を見て、以下の評価基準で判定した:
A:剥がしても、金属がテープ面に映らなかった
B:金属がテープ面に映った
C:金属 及び、繊維くずが、テープ面に映った
汎用的なポリエチレンテレフタレートをスパンボンド法により、紡糸温度300℃でフィラメントの長繊維群を移動捕集面に向けて押し出し、紡糸速度3500m/分で紡糸し、コロナ帯電で3μC/g程度帯電させて充分に開繊させて、平均繊径16μmフィラメントからなる5cm変動率15%以下の均一性を有する未結合長繊維ウェブを、目付12.5g/m2で、捕集ネット面上に、調製した(不織布層A)。
一方、ポリエチレンテレフタレート(溶融粘度ηsp/c 0.50)を、紡糸温度300℃、加熱エア温度320℃、吐出エア1000Nm3/hr/mの条件下で、メルトブロウン法にて紡糸して、平均繊維径1.6μmの極細繊維を、目付5g/m2のランダムウェブとして上記形成の長繊維ウェブに向けて直に噴出させた(極細繊維層B)。この際のメルトブロウンノズルから長繊維ウェブ上面までの距離は、100mmとし、メルトブロウンノズル直下の捕集面における吸引を0.2kPa、風速約7m/secに設定した。次いで、該積層ウェブをフラットとフラットロールの間に通して熱圧着させ、積層不織布を得た。
次いで該積層ウェブをフラットとフラットロールの間に通して熱圧着させ、積層不織布を得た。
上記の方法で得られたポリエステル繊維の積層不織布の第1層、第2層、第3層の繊維径、目付けの基材構成を、以下の表1に示す。上記製造例において得られた電磁波シールドシートは、金属密着性がよく、金属加工後の厚み増加も3μmと少なく、かつ、高いシールド特性を示した。評価結果を同じく以下の表1に示す。得られた電磁波シールドシートは、金属加工後の厚みが30μmと非常に薄く高いシールド特性(65dB)を示した。
実施例1と同様に得たポリエステル繊維の積層不織布を、スパッタリング法により加工し、電磁波シールドシートを得た。スパッタリングは、真空蒸着装置と、熱源としてのニラコ製スタンダートボード(型式:SF-106 タングステン)とを用いて実施した。真空度5×10-5torrで、印加電圧5V、蒸着時間180秒を基本条件とした。
得られた電磁波シールドシートは、積層不織布に使われている極細繊維により金属の裏抜けがなく、繊維表面に均一な金属被膜を形成することができた。評価結果を以下の表1に示す。
実施例1と同様の方法で、紡口径、及び、紡糸温度、紡糸速度、吸引力、風速を変化させ、ポリエステル繊維の1m幅の積層不織布を得た。得られた不織布の性状を、以下の表1に示す。また、実施例1と同様に、無電解メッキ方法で、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果は同じく以下の表1に示す。
実施例3と同じ不織布を用い、無電解メッキの処理時間を短くし、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を以下の表1に示す。
実施例3と同じ不織布を用い、無電解メッキの処理時間を長くし、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を以下の表1に示す。
実施例3と同様の条件で、不織布の目付けと厚みを変化させた積層不織布を得た。得られた不織布の性状を以下の表1に示す。また、実施例1と同様に、無電解メッキ方法で、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を同じく以下の表1に示す。
実施例3と同様の条件で、スパンボンド不織布を得、その後、メルトブロウン不織布の紡口径、及び、紡糸温度、紡糸速度、吸引力、風速を変化させ、メルトブロウン不織布の繊維径を変化させ、その他は実施例3と同様にし、積層不織布を得た。得られた不織布の性状を以下の表1と表2に示す。また、実施例1と同様に、無電解メッキ方法で、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を同じく以下の表1と表2に示す。
メルトブロウン不織布は実施例3と同様にし、スパンボンド不織布の紡口径、及び、紡糸温度、紡糸速度を変化させ、スパンボンド不織布の繊維径を変化させ、その他は実施例3と同様にし、積層不織布を得た。得られた不織布の性状を以下の表2に示す。また、実施例1と同様に、無電解メッキ方法で、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を同じく以下の表2に示す。
熱可塑性樹脂をPPS(ポリプラスチック社製フォートロン)とした。不織布を作る条件は、以下とした。第1層:樹脂の溶融粘度(70g/10分、測定条件:荷重5kg、315.6℃)、紡糸温度:320℃、紡糸速度:(実施例15:8000m/分、実施例16:7500m/分)、第2層:樹脂の溶融粘度(670g/10分、測定条件:荷重5kg、315.6℃)、紡糸温度:340℃、加熱空気温度:390℃、加熱空気量:(実施例15;1000Nm3/hr/m、実施例16:1200Nm3/hr/m)、又フラットロールによる熱接着条件は、線圧260N/cm、ロール温度は上/下=170℃/170℃、カレンダー条件は、線圧350N/cm、ロール温度は上/下=235℃/235℃。積層不織布を作る条件及びその性能を、それぞれ、以下の表2に示す。その他の条件は、実施例1と同様にし、積層不織布を得た。得られた不織布の性状を同じく以下の表2に示す。また、実施例1と同様に、無電解メッキ方法で、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を同じく以下の表2に示す。
実施例3と同様の不織布の作成方法で、第3層を重ねず、他の方法は、実施例3と同様にし、2層タイプの積層不織布を得た(実施例17)。得られた不織布の性状を以下の表2に示す。また、実施例1と同様に、無電解メッキ方法で、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を同じく以下の表2に示す。
同様に、実施例11と同様の不織布の作製方法で、第3層を重ねず、他の方法は、実施例11と同様にし、2層タイプの積層不織布を得た(実施例18)。得られた不織布の性状を以下の表2に示す。また、実施例1を同様に、無電解メッキ方法で、金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を同じく以下の表2に示す。
実施例3と同じポリエステル繊維の1m幅の積層不織布に、実施例2と同様のスパッタリング方法で、銀を金属加工し電磁波シールドシートとした。その性状・電磁波シールド特性を観た。評価結果を以下の表2に示す。また、スパッタリング時間を調整し、表2に示した金属加工量とし、電磁波シールドシートと、その性状・電磁波シールド特性を観た。評価結果を同じく以下の表2に示す。
実施例3と同じポリエステル繊維の1m幅の積層不織布に、実施例2と同様のスパッタリング方法で、アルミニウムを金属加工し電磁波シールドシートとした。以下の表2に示す金属加工量とし、電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を同じく以下の表2に示す。
実施例17と同じ2層タイプの積層不織布に、実施例2と同様のスパッタリング方法で、銀を金属加工し電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を以下の表2に示す。
ポリエステル繊維のサーマルボンド単層不織布(厚み85μm、嵩密度0.23g/cm3)を実施例1と同様に処理し電磁波シールドシート(金属付着量8g/m2、表面抵抗率-0.66Ω/□)を得た。加工性は、加工品の厚みが厚く、シートが硬い為、途中で皺が多発した。又、金属加工後の厚みが90μmになり、小型化された電子機器に使用するには不適切であった。評価結果を以下の表3に示す。
ポリエステル繊維のサーマルボンド単層不織布(厚み85μm、嵩密度0.23g/cm3)を上記と同様に、スパッタリング法により加工し電磁波シールドシート(金属付着量4g/m2、表面抵抗率-0.32Ω/□)を得た。得られた電磁波シールドシートには、極細繊維の層がないため、金属が裏抜けしてしまい金属被膜の均一形成が困難であった。評価結果を以下の表3に示す。
不織布として、旭化成せんい製のスパンボンド不織布(E05025、目付け25g/m2)を用いた。不織布の構成及び性能結果を以下の表3に示す。次に、実施例1と同様の方法で、無電解メッキを行ない金属加工し、電磁波シールドシートとし、その性状・電磁波シールド特性を観た。加工性は、加工品の厚みが厚く、シートが硬い為、途中で皺が多発した。又、金属加工後の厚みが約120μmになり、小型化された電子機器に使用するには不適切であった。評価結果を同じく以下の表3に示す。
不織布として、実施例3、13と14に用いた積層不織布の内、第1層のみの不織布の目付けで、単層の不織布を、それぞれ、比較例4、5と6で、得た。次に、実施例1と同様の方法で、無電解メッキを行ない金属加工し、電磁波シールドシートとし、その性状・電磁波シールド特性を観た。加工性は、加工品の厚みが厚く、シートが硬い為、途中で皺が多発した。又、金属加工後の厚みが厚く、小型化された電子機器に使用するには不適切であった。評価結果を以下の表3に示す。
不織布として、実施例3と11に用いた積層不織布の内、第2層の極細不織布のみの目付け違いの単層の不織布を、それぞれ、比較例7と8で、得た。次に、実施例1と同様の方法で、無電解メッキにて金属加工を行なおうとしたが、金属加工時に、不織布が切れたり、収縮してしまい、良好な連続した電磁波シールドシートは得られなかった。しかしながら、ラボ(実験室)で、不織布に張力をかけずに、メッキ時間のみ時間設定を同じにし、20cm×20cmの試作品を得た。これらのシールド性能を以下の表3に示す。
また、実施例7と同じ不織布を、一定長・幅で固定し、熱セットした不織布を得た(比較例9)。次に、実施例1と同様の方法で、無電解メッキにて金属加工を行なおうとしたが、金属加工時に、不織布の収縮はなかったが、不織布が切れ、良好な連続した電磁波シールドシートは得られなかった。しかしながら、ラボで、不織布に張力をかけずに、メッキ時間のみ時間設定を同じにし、20cm×20cmの試作品を得た。これらのシールド性能を以下の表3に示す。
不織布として、実施例3と同じ積層不織布を用い、メッキ時間を短くし、所望の金属加工量の金属加工シートを得、その性状・電磁波シールド特性を観た。評価結果を以下の表3に示す。
不織布として、旭化成せんい製のスパンボンド不織布(E05025、目付け25g/m2)を用いた。不織布の構成及び性能結果を以下の表3に示す。次に、実施例2と同様の方法で、銀のスパッタリング加工を行ない金属加工し、電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を以下の表3に示す。
不織布として、比較例4と同じ単層の不織布を用い、実施例2と同様の方法で、銀のスパッタリング加工を行ない金属加工し、電磁波シールドシートとし、その性状・電磁波シールド特性を観た。評価結果を以下の表3に示す。
不織布として、実施例3と11に用いた積層不織布の内、第2層の極細不織布のみの目付け違いの単層の不織布を、それぞれ比較例14と15で、得た。次に、実施例2と同様の方法で、銀のスパッタリング加工にて金属加工を行なおうとしたが、金属加工時に、不織布が切れたり、収縮してしまい、良好な連続した電磁波シールドシートは得られなかった。しかしながら、ラボで、不織布に張力をかけずに、金属蒸着時間のみ同じにし、20cm×20cmの試作品を得た。これらのシールド性能を以下の表3に示す。
また、実施例7と同じ不織布を、一定長・幅で固定し、熱セットした不織布を得た(比較例16)。次に、実施例2と同様の方法で、銀のスパッタリング加工にて金属加工を行なおうとしたが、不織布の熱収縮はなかったが、加工時に不織布が切れ、良好な連続した電磁波シールドシートは得られなかった。しかしながら、ラボで、不織布に張力をかけずに、メッキ時間のみ時間設定を同じにし、20cm×20cmの試作品を得た。これらのシールド性能を以下の表3に示す。
不織布として、実施例3と同じ積層不織布を用い、実施例2と同様の銀によるスパッタリング法により、その時間を調整し、金属加工量の少ない加工シートを得、その性状・電磁波シールド特性を観た。評価結果を以下の表3に示す。
Claims (9)
- 少なくとも第1層、及び第2層を有する積層不織布からなる電磁波シールドシートであって、該第1層は、繊維径6~50μmの熱可塑性合成繊維の層であり、該第2層は、繊維径0.1~5.0μmの極細繊維の層であり、そして該シートの少なくとも片面に金属が付着されていることを特徴とする前記シート。
- 繊維径6~50μmの熱可塑性合成繊維の第3層をさらに有する、請求項1に記載の電磁波シールドシート。
- 前記金属の付着が、無電解メッキ又はスパッタリングによる、請求項1に記載の電磁波シールドシート。
- 前記積層不織布の厚みが、10~100μmである、請求項1に記載の電磁波シールドシート。
- 前記不織布の引張強力が20N/3cm以上である、請求項1に記載の電磁波シールドシート。
- 前記不織布全体に対する前記極細繊維の含有率は、12~23wt%である、請求項1に記載の電磁波シールドシート。
- 前記積層不織布の嵩密度は、0.3~0.8g/cm3である、請求項1に記載の電磁波シールドシート。
- 前記積層不織布が、カレンダー処理されている、請求項1に記載の電磁波シールドシート。
- 前記シートの表面抵抗率は、常用対数値で-2.0~-0.2Ω/□である、請求項1に記載の電磁波シールドシート。
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JPWO2017061597A1 (ja) * | 2015-10-07 | 2018-07-26 | 積水化学工業株式会社 | 接着剤層付き金属被覆不織布、接着剤層付き金属被覆不織布の製造方法、及び被覆芯線 |
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JP2019049080A (ja) * | 2017-09-11 | 2019-03-28 | 三菱製紙株式会社 | 電磁波シールド材用不織布基材 |
JP2019049079A (ja) * | 2017-09-11 | 2019-03-28 | 三菱製紙株式会社 | 電磁波シールド材用不織布基材の製造方法 |
JP2021080623A (ja) * | 2021-02-10 | 2021-05-27 | 三菱製紙株式会社 | 電磁波シールド材用不織布基材の製造方法 |
JP7191135B2 (ja) | 2021-02-10 | 2022-12-16 | 三菱製紙株式会社 | 電磁波シールド材用不織布基材の製造方法 |
Also Published As
Publication number | Publication date |
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EP2458952A1 (en) | 2012-05-30 |
JPWO2011010697A1 (ja) | 2013-01-07 |
US20120111627A1 (en) | 2012-05-10 |
EP2458952B1 (en) | 2014-12-31 |
TWI407901B (zh) | 2013-09-01 |
KR101254908B1 (ko) | 2013-04-19 |
CN102474998B (zh) | 2014-12-10 |
EP2458952A4 (en) | 2013-08-21 |
CN102474998A (zh) | 2012-05-23 |
US9233517B2 (en) | 2016-01-12 |
TW201112940A (en) | 2011-04-01 |
JP5722775B2 (ja) | 2015-05-27 |
KR20120024971A (ko) | 2012-03-14 |
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