WO2011093091A1 - アンテナ部品とその製造方法 - Google Patents
アンテナ部品とその製造方法 Download PDFInfo
- Publication number
- WO2011093091A1 WO2011093091A1 PCT/JP2011/000476 JP2011000476W WO2011093091A1 WO 2011093091 A1 WO2011093091 A1 WO 2011093091A1 JP 2011000476 W JP2011000476 W JP 2011000476W WO 2011093091 A1 WO2011093091 A1 WO 2011093091A1
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- Prior art keywords
- antenna component
- hollow part
- resin
- antenna
- manufacturing
- Prior art date
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q7/00—Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop
- H01Q7/06—Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop with core of ferromagnetic material
- H01Q7/08—Ferrite rod or like elongated core
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/045—Fixed inductances of the signal type with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
-
- G—PHYSICS
- G04—HOROLOGY
- G04R—RADIO-CONTROLLED TIME-PIECES
- G04R60/00—Constructional details
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F2003/005—Magnetic cores for receiving several windings with perpendicular axes, e.g. for antennae or inductive power transfer
Definitions
- Embodiments of the present invention relate to an antenna component and a manufacturing method thereof.
- the frequency band of radio waves used for information propagation in current mobile communication terminals is a high frequency region of 100 MHz or more.
- radio waves in the high frequency range of the GHz band are used. For this reason, electronic components useful in the high frequency region are required.
- antenna devices In order to cope with radio waves in a high frequency range, electronic parts are required to have small energy loss and transmission loss and to effectively shorten the electrical characteristic length.
- loss occurs in conductors and materials during reception. This loss causes a decrease in reception sensitivity.
- antenna devices are required to be downsized while maintaining reception sensitivity while suppressing loss. For example, in information communication using a frequency band of 100 MHz to 1 GHz such as terrestrial digital broadcasting, a small antenna having excellent reception sensitivity is required.
- a dielectric body (or magnetic body) made of a rectangular parallelepiped is wound.
- a radio-controlled watch antenna a rectangular parallelepiped magnetic body is insulated by a heat-shrinkable tube, and a coil is wound around it, or a coil is wound around a rectangular parallelepiped core in which magnetic powder is solidified with resin.
- a rotating antenna is known.
- the antenna soft magnetic powder it is known to use a fine soft magnetic powder having an average particle diameter of 1 ⁇ m or less, for example.
- the magnetic material obtained by solidifying soft magnetic powder with resin is expected as a magnetic core material for antennas with low loss in the high frequency range, the maintenance of the shape of the magnetic core material, the winding property of the coil around the magnetic core material, There is a difficulty in ensuring insulation between the magnetic core material and the coil.
- the problem to be solved by the present invention is to provide an antenna component that has low loss in the high frequency region, and that has improved the maintainability of the shape of the magnetic core material and the winding property of the coil around the magnetic core material, and a manufacturing method thereof. It is to provide.
- the antenna component according to the embodiment includes a cylindrical part having an inner dimension R2, a partition part provided at one end of the cylindrical part, and an open part provided at the other end of the cylindrical part.
- the partition wall is provided with a hole having a dimension R1 that satisfies 0.05 mm ⁇ R1 ⁇ 0.5 mm and R1 ⁇ R2.
- FIG. 1 is a perspective view showing an antenna component of the embodiment.
- 2 to 6 are cross-sectional views showing a hollow part into which a magnetic core material is inserted in the antenna part of the embodiment.
- 1 is an antenna component
- 2 is a magnetic core material
- 3 is a hollow component
- 4 is a coil.
- the antenna component 1 has a magnetic core material 2 inserted into a hollow component 3.
- the magnetic core material 2 is obtained by curing a mixture of soft magnetic powder and resin.
- a coil 4 is wound around the outer periphery of the hollow part 3 in which the magnetic core material 2 is inserted.
- the antenna component 1 is configured.
- the soft magnetic powder constituting the magnetic core material 2 is preferably made of a magnetic material having a high magnetic permeability in a high frequency range.
- Soft magnetic powders are iron aluminum silicon alloy (Sendust), iron nickel alloy (permalloy), iron nickel molybdenum alloy (molybdenum permalloy), iron cobalt alloy, iron cobalt silicon alloy, iron silicon vanadium alloy, iron cobalt boron alloy, cobalt It is preferably made of at least one selected from a base amorphous alloy, an iron base amorphous alloy, carbonyl iron, carbonyl nickel, carbonyl cobalt, iron, nickel, and cobalt.
- the soft magnetic powder may have a core-shell structure whose surface is covered with a film.
- the coating is preferably made of at least one selected from nitrides, carbides, and oxides.
- nitrides As a constituent material of the coating, Al, Si, Mg, Ca, Sr, Ba, Ti, Zr, Hf, Zn, Mn, and an oxide containing at least one metal selected from rare earth elements, AlN, Si 3 N 4 , SiC and the like.
- the coating may be formed by directly nitriding, carbonizing, or oxidizing the surface of the soft magnetic powder.
- the surface of the soft magnetic powder By covering the surface of the soft magnetic powder with a film, it is possible to suppress deterioration of characteristics due to oxidation or the like.
- a metal film having excellent corrosion resistance such as a resin film or a Ni plating film may be applied.
- Resin coating is polyester, polyethylene, polystyrene, polyvinyl chloride, polyvinyl butyral, polyurethane, cellulose resin, acrylonitrile-butadiene rubber, styrene-butadiene rubber, epoxy resin, phenol resin, ABS resin, amide resin, imide resin Or a copolymer thereof is preferred.
- the thickness of the film is preferably in the range of 1 nm to 100 nm.
- the soft magnetic powder is a fine powder having an average particle size of 10 nm or more and less than 100 nm
- the thickness of the coating is preferably thin, and specifically, it is preferably in the range of 1 nm or more and 7 nm or less.
- the coated soft magnetic powder is called core-shell type soft magnetic powder.
- the average particle size of the soft magnetic powder is not particularly limited, but is preferably in the range of 10 nm to 1 ⁇ m. It is difficult to prepare a soft magnetic powder having an average particle size of less than 10 nm. When the average particle size of the soft magnetic powder exceeds 1 ⁇ m, the high frequency characteristics of the antenna are degraded.
- the average particle size of the soft magnetic powder is preferably 100 nm or less.
- the average particle size of the soft magnetic powder is preferably less than 50 nm.
- soft magnetic powder having an average particle size of 100 nm or less is referred to as nano metal particles.
- the soft magnetic powder having an average particle diameter of 1 ⁇ m or less, and nano metal particles having an average particle diameter of 100 nm or less are effective. That is, eddy current loss can be suppressed by using fine soft magnetic powder as a constituent material of the magnetic core.
- the soft magnetic powder is preferably nanometal particles having an average particle size of 100 nm or less.
- nano metal particles examples include nickel powder, cobalt powder, iron powder, etc., obtained by thermally reducing a fine oxide obtained by thermally decomposing organic acid salts such as nickel, cobalt and iron oxalate with hydrogen. And fine iron powder obtained by neutralizing ferrous sulfate solution.
- a metal such as nickel, cobalt, or iron is heated and evaporated under reduced pressure and solidified in a gas phase to obtain nickel powder, cobalt powder, iron powder, or the like.
- These methods are not limited to fine powders such as nickel, cobalt, iron, etc., but can also be applied to alloys thereof and alloys added with metals having a low standard Gibbs energy of oxides such as Al and Si.
- the nano metal particles may be fine powder reduced in a solution, such as nickel powder or cobalt powder obtained by hydrogen reduction of a solution containing ammonia complex ions of nickel or cobalt at high temperature and high pressure.
- a solution such as nickel powder or cobalt powder obtained by hydrogen reduction of a solution containing ammonia complex ions of nickel or cobalt at high temperature and high pressure.
- it may be carbonyl nickel powder or carbonyl iron powder obtained by thermal decomposition of nickel carbonyl (Ni (CO) 4 ) or iron carbonyl (Fe (CO) 5 ). Since the powder having an average particle size of less than 100 nm is extremely fine, it is preferable to provide the above-described coating as a protective layer to prevent deterioration of the soft magnetic powder due to oxidation or the like.
- the resin used as the binder of the soft magnetic powder is not particularly limited, but polyester, polyvinyl chloride, polyvinyl butyral, polyurethane, cellulosic resin, acrylonitrile-butadiene rubber, styrene-butadiene rubber, and their Examples thereof include thermoplastic resins such as copolymers, thermosetting resins such as epoxy resins, phenol resins, amide resins, and imide resins, or halides and brominated polymers that are organic flame retardants. These may be used alone or in combination of two or more.
- an epoxy resin or a polyimide resin having a high oxygen barrier property is more preferable.
- the hollow part 3 includes a cylindrical part 5 whose inner dimension is R ⁇ b> 2, a partition wall part 6 provided at one end of the cylindrical part 5, and a cylindrical part 5. And an opening 7 provided at the other end. 2 to 6, the illustration of the coil 4 is omitted.
- the shape of the cylindrical portion 5 of the hollow part 3 is not particularly limited, and may be any of a cylindrical shape (including an ellipse) and a rectangular tube shape.
- the cylindrical part 5 of the hollow part 3 preferably has a cylindrical shape. In the case of the cylindrical hollow part 3, since the distance between the hollow part 3 and the coil 4 can be made constant when the coil 4 is wound around the outer periphery thereof, the antenna characteristics can be improved.
- the dimension R2 inside the cylindrical part 5 indicates the inner diameter (diameter) of the cylindrical shape.
- the inner dimension R2 of the cylindrical part 5 indicates the minimum inner dimension of the rectangular tube shape. For example, when the cross section of the rectangular tubular portion 5 is a quadrangle, the length of the minimum side of the square cross section is indicated. Similarly, when the cylindrical portion 5 has a polygonal cross section, the inner minimum distance is indicated.
- the dimension R2 of the cylindrical part 5 corresponds to the inner dimension (such as the inner diameter of the cylindrical cylindrical part 5) of the open part 7 that serves as an insertion port for the magnetic core material 2.
- the wall thickness of the hollow part 3 is preferably in the range of 0.05 to 0.85 mm.
- the thickness of the hollow part 3 is less than 0.05 mm, the strength of the hollow part 3 tends to be insufficient. If the thickness of the hollow part 3 exceeds 0.85 mm, the distance between the magnetic core material 2 and the coil 4 will be too far, and the antenna characteristics may be deteriorated.
- the thickness of the hollow part 3 is more preferably in the range of 0.1 to 0.5 mm.
- the hollow part 3 maintains the shape of the magnetic core material 2 inserted into the hollow part 3 and protects the magnetic core material 2, and serves as a case (bobbin) for the magnetic core material 2.
- a hole 8 having a dimension R1 (R1 ⁇ R2) smaller than the dimension R2 of the hollow part is formed in the partition wall part 6 provided at one end of the cylindrical part 5 of the hollow part 3.
- the shape of the hole 8 is not particularly limited, and examples thereof include a circle, an ellipse, and a polygon.
- the dimension R1 of the hole 8 is in a range of 0.05 mm ⁇ R1 ⁇ 0.5 mm.
- the dimension R1 of the hole 8 is more preferably in the range of 0.1 mm ⁇ R2 ⁇ 0.35 mm.
- the dimension R1 of the hole 8 indicates a diameter when the shape is circular, a short diameter when the shape is elliptical, and a minimum inner dimension when the shape is polygonal.
- the hollow part is due to the high viscosity of the mixture. It is difficult to fill the mixture without gaps. Furthermore, when the mixture is filled in the hollow part, the air in the hollow part is engulfed and a large gap is likely to be generated in the hollow part. If a large gap is generated in the hollow part, the distance between the magnetic core material and the coil is increased, and the distance becomes non-uniform, which causes a decrease in antenna characteristics.
- the hollow component 3 can be filled with the mixture of the soft magnetic powder and the resin without any gaps. If the dimension R1 of the hole 8 is less than 0.05 mm, the air in the hollow part 3 cannot be discharged efficiently. On the other hand, when the dimension R1 of the hole 8 exceeds 0.5 mm, the mixture flows out of the hole 8 and an appearance defect tends to occur.
- the dimensions of the magnetic core material 2 are not particularly limited.
- the diameter is preferably in the range of 1 to 5 mm and the length is preferably in the range of 10 to 100 mm.
- the magnetic core material 2 may have a prismatic shape corresponding to the shape of the cylindrical portion 5 of the hollow part 3.
- the dimensions conform to the dimensions of the cylindrical magnetic core material 2. That is, the shape of the magnetic core material 2 having a quadrangular prism shape is preferably such that the length of one side (short side in the case of a rectangle) is 1 to 5 mm and the length is 10 to 100 mm.
- the shape of the hollow part 3 is adjusted according to the shape of such a magnetic core material 2.
- the second hole 9 is provided in the side wall portion (tubular portion 5) of the hollow part 3.
- the shape of the second hole 9 is the same as that of the first hole 8.
- the dimension R3 of the second hole 9 is preferably in the range of 0.05 mm ⁇ R3 ⁇ 0.5 mm, more preferably 0.1 mm ⁇ R3 ⁇ 0. The range is 35 mm.
- the dimension R3 of the second hole 9 has the same meaning as the dimension R1 of the first hole 8.
- FIG. 3 shows an example in which one hole 9 is provided in the cylindrical part 5, a plurality of holes 9 may be provided in the cylindrical part 5 as necessary.
- the hole 8 in the partition wall portion 6 of the hollow part 3 the air existing inside the hollow part 3 is allowed to escape from the hole 8 and the mixture of the soft magnetic powder and the resin is injected. Can do. Therefore, it is possible to suppress the gap generated in the hollow part 3. Furthermore, by providing the hole 9 also in the cylindrical part 5, the space
- an area where the magnetic core material 2 and the inner surface of the hollow component 3 are in contact with each other is defined as the inner periphery of the hollow component 3 (the circumference of the inner surface of the cylindrical tubular portion 5, etc. ) To 50% or more.
- the method of measuring the region where the magnetic core material 2 and the inner surface of the hollow part 3 are in contact is to arbitrarily cut the hollow part 3 in which the magnetic core material 2 is inserted, and in the cross section, the inner surface of the hollow part 3 and the magnetic core material 2 Observe whether or not is touching.
- the ratio of the area where the magnetic core material 2 is in contact with the circumference of the inner surface of the hollow part 3 (when the cylindrical portion 5 is cylindrical) as 100% is measured.
- region which has contacted with respect to the inner periphery of an inner surface shall be shown.
- the region where the magnetic core material 2 and the inner surface of the hollow part 3 are in contact is more preferably 70% or more and 100% or less with respect to the inner periphery of the hollow part 3. According to the antenna component 1 of this embodiment, the filling state of the magnetic core material 2 into the hollow component 3 can be obtained with good reproducibility.
- the partition wall 6 of the hollow part 3 may be arranged so as to be shifted from the outermost end of the cylindrical part 5 to the inner side (opening part 7 side of the hollow part 3).
- an extended portion 10 in which the tubular portion 5 is extended outward is formed on the end portion side of the hollow part 3 where the partition wall portion 6 is disposed.
- L1 is the length of the hollow part 3 in the longitudinal direction
- L2 is the length of the extension 10 in the same direction.
- the hollow component 3 shown in FIG. 4 has a structure in which the partition wall 6 is provided on the inner side by the length L2 of the extension 10.
- the mixture of soft magnetic powder and resin When the mixture of soft magnetic powder and resin is injected into the hollow part 3, the air present inside the hollow part 3 escapes from the holes 8. At this time, the mixture may protrude from the hole 8 depending on the viscosity of the mixture and the injection pressure. If the mixture protrudes too much, the appearance becomes poor, and an extra step of removing the protruding mixture is required.
- the partition wall portion 6 on the inner side and forming the extension portion 10 even if the mixture protrudes from the hole 8, the mixture does not protrude from the outer surface of the hollow part 3 as long as the amount is small. If the mixture does not protrude from the outer surface of the hollow part 3, it will not be defective in appearance, so that the manufacturing process can be easily managed.
- the length L2 of the extension 10 is not particularly limited, but is preferably in the range of 0.1 to 3 mm. If the length L2 of the extension 10 exceeds 3 mm, the number of regions that are not filled with the magnetic core material 2 increases, so that the characteristics of the antenna component 1 deteriorates or the antenna component 1 becomes larger than necessary. End up. When the length L2 of the extension 10 is less than 0.1 mm, the effect of providing the extension 10 cannot be sufficiently obtained.
- FIG. 5 shows a hollow part 3 having a thick extension 10.
- the mixture may be molded in advance according to the shape of the hollow part 3 and further hardened before being inserted into the hollow part 3. Good.
- the shape of the hollow part 3 is cylindrical, the mixture is formed into a columnar shape and cured.
- the shape of the hollow part 3 is a rectangular tube shape, the mixture is formed into a prismatic shape (such as a quadrangular column) and cured.
- the shape of the hardened body of the mixture is larger than the shape of the hollow part 3, it is necessary to process according to the shape of the hollow part 3.
- the yield tends to decrease due to cracks or chips.
- the shape of the cured body is the same as the shape of the hollow part 3 (the shape of the open portion 7), it may be difficult to insert the cured body into the hollow part 3.
- the shape is preferably slightly smaller than the shape of the hollow part 3.
- the dimension of the cured body is preferably smaller than the dimension R2 of the hollow part 3 in the range of 0.1 to 0.3 mm.
- Filling the gap with resin is not limited to using a cured body.
- FIG. 6 shows a hollow part 3 in which a magnetic core material (molded body) 2 obtained by previously molding and curing a mixture of soft magnetic powder and resin is inserted, and a resin 11 is filled in a gap with the magnetic core material 2.
- the hollow part 3 shown in FIG. 6 has the extension part 10, the hollow part 3 which does not have the extension part 10 naturally may be sufficient.
- FIG. 6 shows a state in which the resin 11 is filled in the gap on the open part 7 side of the hollow part 3, but the resin 11 may be filled only in the gap between the inner surface of the cylindrical part 5 and the magnetic core material 2. .
- the resin 11 that fills the gap between the magnetic core material 2 and the hollow part 3 is the same as the resin constituting the magnetic core material 2, such as polyester, polyvinyl chloride, polyvinyl butyral, polyurethane, cellulosic resin, acrylonitrile-butadiene rubber, styrene.
- -Thermoplastic resins such as butadiene rubber and copolymers thereof, epoxy resins, phenol resins, amide resins, imide resins, or organic flame retardant halides, brominated polymers, etc. Illustrated. These are used as one kind or a mixture of two or more kinds.
- an epoxy resin or a polyimide resin having a high oxygen barrier property is preferable.
- a coil 4 is wound around the outer periphery of the hollow part 3 in which the magnetic core material 2 is inserted.
- a metal wire, a metal foil, a metal film, or the like is used for the coil 4 .
- the coil 4 may have an insulating coating on its surface.
- winding used as the coil 4 is arbitrary, the metal wire whose diameter is 1 mm or less or the metal foil whose width is 2 mm or less and thickness is 0.5 mm or less is preferable.
- the metal film a film formed by a film forming method such as plating, sputtering, or CVD is used.
- the width of the metal film is preferably 2 mm or less, and the thickness is preferably 1 mm or less.
- the diameter of the metal wire is preferably 0.1 mm or more.
- the metal foil preferably has a width of 0.2 mm or more and a thickness of 0.02 mm or more.
- the metal film preferably has a width of 0.1 mm or more and a thickness of 0.01 mm or more. Windings smaller than this size are difficult to manufacture and may increase the manufacturing cost.
- the antenna component 1 of this embodiment is suitable for a radio signal antenna of 100 MHz or higher because it has excellent antenna characteristics, and can be expected to reduce the electrical characteristic length.
- the upper limit of the frequency depends on the characteristics of the magnetic core material 2, it is about 3 GHz if the magnetic permeability of the soft magnetic powder is effective.
- Magnetic materials effective up to about 3 GHz include iron aluminum silicon alloy, iron nickel alloy, iron nickel molybdenum alloy, iron cobalt alloy, iron cobalt silicon alloy, iron silicon vanadium alloy, iron cobalt boron alloy, cobalt base Examples include amorphous alloys, iron-based amorphous alloys, carbonyl iron, molybdenum permalloy, and pure iron powder.
- Such an antenna component 1 can be applied to electronic devices having various communication functions.
- the antenna can be reduced in size and thickness, and the antenna characteristics can be further improved. Since the antenna component 1 is effective in a high-frequency region of 100 MHz or more, the reception characteristics can be improved by using the antenna component 1 for a wireless communication electronic device such as a wireless LAN electronic device, a digital terrestrial broadcasting electronic device, or a mobile phone. In addition, the characteristics of the electronic device can be improved.
- the antenna component 1 is effective for communication devices that use radio waves in a frequency range of 100 MHz to 3 GHz, and further 100 MHz to 1 GHz.
- FIG. 7 is a cross-sectional view showing the manufacturing process of the antenna component according to the first embodiment
- FIG. 8 is a cross-sectional view showing the manufacturing process of the antenna component according to the second embodiment.
- the method for manufacturing the antenna component 1 is not limited to the manufacturing method shown here. Here, a method for efficiently manufacturing the antenna component 1 will be described.
- the method for manufacturing an antenna component according to the first embodiment includes a cylindrical portion having an inner dimension R2, a partition wall portion provided at one end portion of the cylindrical portion, and a second end portion of the cylindrical portion.
- a step of preparing a hollow part having a formed open part, a step of filling a mixture of soft magnetic powder and resin into the hollow part from the open part, and a resin in the mixture filled in the hollow part A step of curing, and a step of winding a coil around the outer periphery of the hollow part.
- the partition wall is provided with a hole having a dimension R1 that satisfies 0.05 mm ⁇ R1 ⁇ 0.5 mm and R1 ⁇ R2.
- soft magnetic powder and resin are mixed.
- the configuration of the soft magnetic powder is as described above. Further, the type of resin and the like are as described above.
- the viscosity of the resin is preferably in the range of 0.5 to 3 Pa ⁇ s at room temperature. When the viscosity of the resin is less than 0.5 Pa ⁇ s, the viscosity is too small, and the mixture easily flows out from the hole 8 provided in the partition wall portion 6 of the hollow part 3. On the other hand, when the viscosity of the resin exceeds 3 Pa ⁇ s, the viscosity is too high and it becomes difficult to fill the inside of the hollow part 3. In addition, there is a problem that uniform mixing with the soft magnetic powder takes time. It is preferable to mix the soft magnetic powder and the resin while performing a vacuum defoaming treatment. By mixing in vacuum, air is suppressed from being mixed into the mixture of the soft magnetic powder and the resin.
- the hollow part 3 having the partition wall 6 in which the holes 8 are formed is prepared.
- the details of the shape of the hollow part 3 are as described above.
- a mixture 12 of soft magnetic powder and resin is filled from the opening 7 of the hollow part 3.
- the viscosity of the resin is more preferably in the range of 0.5 to 2 Pa ⁇ s at room temperature.
- air can easily escape from the holes 8 of the partition wall part 6.
- the mixture is preferably vacuum impregnated to prevent excess air from entering. Furthermore, by providing a hole in the side wall portion (tubular portion) of the hollow part 3, the air existing inside the hollow part 3 can be efficiently discharged. As a result, the mixture 12 can be filled without forming a void in the hollow part 3.
- the resin in the mixture 12 is cured.
- the curing step is performed according to the resin.
- a thermosetting resin heat is applied to cure the resin.
- an ultraviolet curable resin the resin is cured by irradiating ultraviolet rays.
- the coil 4 is wound around the outer periphery of the hollow part 3.
- the windings constituting the coil 4 are as described above. After the coil 4 is wound, a resin coating may be applied to the surface to ensure insulation.
- the method for manufacturing an antenna component according to the second embodiment includes a cylindrical part having an inner dimension R2, a partition part provided at one end of the cylindrical part, and a second end of the cylindrical part.
- a step of preparing a hollow part having a formed open part, a step of forming and curing a mixture of soft magnetic powder and the first resin to obtain a formed body, and a formed body from the open part into the hollow part A step of inserting, a step of filling the gap between the hollow part and the molded body with the second resin, a step of curing the second resin, and a step of winding a coil around the outer periphery of the hollow part To do.
- the partition wall is provided with a hole having a dimension R1 that satisfies 0.05 mm ⁇ R1 ⁇ 0.5 mm and R1 ⁇ R2.
- soft magnetic powder and resin are mixed.
- the configuration of the soft magnetic powder is as described above. Further, the type of resin and the like are as described above.
- a mixture of soft magnetic powder and resin is molded into a desired shape and then cured to form a molded body.
- the molded body 13 is inserted from the open part 7 of the hollow part 3.
- the size of the molded body 13 is preferably smaller than the dimension R2 of the hollow part 3 in the range of 0.1 to 0.3 mm.
- the gap between the molded body 13 and the hollow part 3 is filled with the resin 14.
- the resin 14 filling the gap is preferably the same as the resin constituting the mixture in order to improve the familiarity with the molded body 13.
- the viscosity of the resin is preferably in the range of 0.05 to 3 Pa ⁇ s, more preferably in the range of 0.5 to 2 Pa ⁇ s at room temperature in order to prevent voids from being generated in the hollow part 3. .
- the resin 14 filled in the gap between the molded body 13 and the hollow part 3 is cured.
- the curing step is performed according to the resin.
- the specific curing process is the same as in the first embodiment.
- the coil 4 is wound around the outer periphery of the hollow part 3.
- the windings constituting the coil 4 are as described above. After winding the coil 4, a resin coating may be applied to ensure insulation.
- Example 1 Argon was introduced as a plasma generating gas at a rate of 40 L / min into the chamber of the high frequency induction thermal plasma apparatus to generate plasma.
- the plasma in the chamber is mixed with Fe powder having an average particle diameter of 10 ⁇ m and Al powder having an average particle diameter of 3 ⁇ m, together with argon (carrier gas) so that the ratio of Fe to Al is 20: 1 by mass ratio.
- argon carrier gas
- acetylene gas was introduced into the chamber together with a carrier gas as a raw material for carbon coating. In this way, nanoparticles in which FeAl alloy particles were coated with carbon were obtained.
- the carbon-coated FeAl alloy nanoparticles are reduced at 600 ° C. under a hydrogen flow of 500 mL / min, cooled to room temperature, and then taken out into an argon atmosphere containing 0.1% by volume of oxygen and oxidized.
- a core-shell type soft magnetic powder was produced.
- the obtained core-shell type soft magnetic powder had a structure in which the average particle size of the soft magnetic powder as the core was 15 nm and the thickness of the oxide film was 3 nm.
- the obtained core-shell type soft magnetic powder and an epoxy resin having a viscosity at room temperature of 2.5 Pa ⁇ s were mixed in a vacuum.
- the ratio of the soft magnetic powder was 40% by volume.
- This mixture was filled into a hollow part made of liquid crystal polymer.
- the hollow part has a cylindrical shape, and each part has an inner diameter R2 of 2 mm, a length L1 of 30.5 mm, a hole diameter R1 of the partition wall part of 0.3 mm, and a wall thickness of 0. 1 mm.
- This hollow part does not have an extension. Filling of the mixture was carried out by natural falling with the open part of the hollow part facing up. Thereafter, the epoxy resin was cured by heating.
- a polyurethane-coated wire having a diameter of 0.3 mm was wound around such a hollow part (direct winding / 15 turns) to form a coil.
- the antenna component of Example 1 was produced.
- Examples 2 and 3 As shown in Tables 1 and 2, antenna components were produced in the same manner as in Example 1 except that the diameter R1 of the hole in the partition wall, the presence / absence and length L2 of the extension, and the viscosity of the resin were changed.
- Example 4 A core-shell type soft magnetic powder having an average particle size of 10 nm as a core was manufactured by the same manufacturing method as in Example 1.
- the core-shell soft magnetic powder and the epoxy resin were mixed while being subjected to vacuum defoaming treatment so that the ratio of the core-shell soft magnetic powder was 35% by volume.
- the obtained mixture was molded into a rectangular column shape of 2.25 mm long ⁇ 2.25 mm wide ⁇ 25 mm long, and the resin was further cured to form a molded body.
- the hollow part was formed of a liquid crystal polymer having a wall thickness of 0.1 mm.
- the diameter R1 of the hole in the partition wall was 0.4 mm, and the extension was not provided.
- Example 4 After curing the resin filled in the gap by heating, a polyurethane-coated wire having a diameter of 0.3 mm was wound around the outer periphery of the hollow part (direct winding / 15 turns) to form a coil. Thus, the antenna component of Example 4 was produced.
- Example 5 As shown in Tables 1 and 2, the antenna component was fabricated in the same manner as in Example 4 except that the diameter R1 of the hole in the partition wall of the hollow component was 0.05 mm and the length L2 of the extension was 0.2 mm. Produced.
- the resin to be vacuum impregnated in the gap between the hollow part and the molded body was an epoxy resin having a viscosity (room temperature) of 1 Pa ⁇ s.
- Example 6 As shown in Table 1 and Table 2, the diameter R1 of the hole in the partition wall is 0.5 mm, the length L2 of the extension is 0.3 mm, and the side wall (tubular portion) has a diameter R3 of 0.1 mm.
- An antenna component was fabricated in the same manner as in Example 4 except that a hollow component provided with one hole was used. The hole of the cylindrical portion was provided at a half of the length L1.
- the resin to be vacuum impregnated in the gap between the hollow part and the molded body was an epoxy resin having a viscosity (room temperature) of 0.8 Pa ⁇ s.
- Example 7 A core-shell type soft magnetic powder having an average particle size of 10 nm as a core was manufactured by the same manufacturing method as in Example 1. The core-shell soft magnetic powder and the epoxy resin were mixed while being subjected to vacuum defoaming treatment so that the ratio of the core-shell soft magnetic powder was 45% by volume. Next, the obtained mixture was molded into a cylindrical shape with a diameter of 2 mm and a length of 35 mm, and the resin was cured to obtain a molded body.
- the hollow part has a cylindrical shape with a diameter R2 of the open portion of 2.2 mm and a length L1 of 36.5 mm.
- the hollow part was formed of a liquid crystal polymer having a wall thickness of 0.1 mm.
- the diameter R1 of the hole in the partition wall was 0.1 mm, and the extension was not provided.
- the hollow part has three holes provided in the cylindrical part.
- the diameter R3 of the hole was 0.05 mm.
- One cylindrical hole was formed at 30% and 70% of L1, and one hole was formed at 50% of L1 on the opposite side (1/2 of L1).
- the gap was vacuum impregnated with an epoxy resin having a viscosity (room temperature) of 0.08 Pa ⁇ s. After curing the resin filled in the gap by heating, a polyurethane-coated wire having a diameter of 0.3 mm was wound around the outer periphery of the hollow part (direct winding / 17 turns) to form a coil.
- the antenna component of Example 7 was produced.
- Example 8 As shown in Table 1 and Table 2, the diameter R3 of the hole in the cylindrical part of the hollow part is changed to 0.3 mm, the length L2 of the extension part is changed to 0.7 mm, and the wall thickness of the extension part is 0.2 mm.
- An antenna component was manufactured in the same manner as in Example 7 except that the thickness was increased.
- the resin that was vacuum impregnated into the gap between the hollow part and the molded body was an epoxy resin having a viscosity (room temperature) of 0.4 Pa ⁇ s.
- Example 9 As shown in Tables 1 and 2, the diameter R3 of the hole in the cylindrical part of the hollow part is changed to 0.5 mm, the length L2 of the extension part is changed to 1.2 mm, and the wall thickness of the extension part is 0.2 mm.
- An antenna component was manufactured in the same manner as in Example 7 except that the thickness was increased.
- the resin to be vacuum impregnated in the gap between the hollow part and the molded body was an epoxy resin having a viscosity (room temperature) of 1 Pa ⁇ s.
- Example 1 An antenna component was produced in the same manner as in Example 1 except that a hollow component in which no hole was formed in the partition wall was used.
- Example 2 An antenna component was manufactured in the same manner as in Example 1 except that a hollow component having a diameter R1 of the partition wall hole increased to 0.7 mm was used.
- Examples 1 to 9 and Comparative Examples 1 to 2 were produced.
- the ratio of defective appearance, the filling ratio of resin, and antenna characteristics were examined.
- the results are shown in Table 2.
- the ratio of the appearance defect is that when the hole in the partition wall part and the side wall part are provided, the mixture of the soft magnetic powder and the resin or the resin filled in the gap leaked from the hole in the side wall part by 0.1 mm or more.
- the proportion of things was investigated. When there was no leakage of 0.1 mm or more, it was indicated as a non-defective product ( ⁇ ), and when there was a leakage of 0.1 mm or more, it was indicated as defective ( ⁇ ).
- the resin filling ratio was determined by cutting an arbitrary cross section of the antenna component and setting the inner surface of the hollow component to 100% in the region where the inner surface of the hollow component and the resin (mixture of soft magnetic powder and resin) were in contact with each other. Investigated at the rate of time.
- each antenna component was vibrated at an acceleration of 43.2 m / s 2 , a frequency of 33.3 Hz, XYZ directions (3 directions) and 3 hours in each direction, and the radiation efficiency of the antenna decreased by -2 dB or more before and after the vibration load.
- the presence or absence of improper fixing of the magnetic core material (a product obtained by curing a mixture of soft magnetic powder and resin) was examined. Those whose radiation efficiency decreased by -2 dB or more, or those in which fixing failure occurred were indicated as defective (x), and those whose radiation efficiency did not decrease by -2 dB or more, or those in which fixing failure did not occur were indicated as non-defective products ( ⁇ ).
- the decrease in radiation efficiency was measured as a value compared with a dipole antenna.
- a dipole antenna a coaxial cable having a center line (center conductor) and a net line (outer conductor) drawn by a copper wire (diameter 2 mm) each having a length of 15 cm to have a total length of 30 cm is used.
- the drawn copper wire is called an antenna element (element). If there is an electric field in the space, a potential difference occurs between both ends of the antenna element, and radio waves flow into the coaxial cable.
- the reason why the antenna element is 15 cm ⁇ 2 and the total length is 30 cm is that the radio wave to be received is set to 500 MHz, and is set based on the value of half of the wavelength of 500 MHz ( ⁇ / 2).
- a dipole antenna (standard antenna) is connected to an electronic device such as a terrestrial digital tuner to measure the reception intensity at all azimuth angles.
- the antenna facing the standard antenna measures horizontal and vertical polarization.
- the antenna (Example and Comparative Example) which measures a standard antenna, and the receiving intensity of all azimuths is measured.
- the ratio of the radiation power of the antenna of each example and the radiation power of the standard antenna is defined as radiation efficiency.
- the antenna parts according to Examples 1 to 9 are all excellent in vibration resistance because there is no appearance defect and the contact area between the magnetic core material and the hollow part is large. Accordingly, it is possible to provide an antenna component that is small and has high performance and excellent durability.
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Abstract
Description
高周波誘導熱プラズマ装置のチャンバ内に、プラズマ発生用ガスとしてアルゴンを40L/分で導入してプラズマを発生させた。このチャンバ内のプラズマに、平均粒径が10μmのFe粉末と平均粒径が3μmのAl粉末とを、FeとAlとの比率が質量比で20:1になるようにアルゴン(キャリアガス)と共に3L/分で噴射した。同時に、チャンバ内に炭素被覆の原料としてアセチレンガスをキャリアガスと共に導入した。このようにして、FeAl合金粒子を炭素で被覆したナノ粒子を得た。
表1および表2に示すように、隔壁部の穴の直径R1、延長部の有無と長さL2、樹脂の粘度を変更する以外は、実施例1と同様にしてアンテナ部品を作製した。
実施例1と同様な製造方法によって、コアである軟磁性体粉末の平均粒径が10nmのコアシェル型軟磁性体粉末を製造した。コアシェル型軟磁性体粉末の比率が35体積%となるように、コアシェル型軟磁性体粉末とエポキシ樹脂とを真空脱泡処理しながら混合した。次に、得られた混合物を縦2.25mm×横2.25mm×長さ25mmの四角柱形状に成形し、さらに樹脂を硬化させて成形体とした。
表1および表2に示すように、中空部品の隔壁部の穴の直径R1を0.05mm、延長部の長さL2を0.2mmとする以外は、実施例4と同様にしてアンテナ部品を作製した。中空部品と成形体との隙間に真空含浸する樹脂は、粘度(常温)が1Pa・sのエポキシ樹脂とした。
表1および表2に示すように、隔壁部の穴の直径R1を0.5mm、延長部の長さL2を0.3mmとし、また側壁部(筒状部)に直径R3が0.1mmの穴を1個設けた中空部品を用いる以外は、実施例4と同様にしてアンテナ部品を作製した。筒状部の穴は長さL1の1/2のところに設けた。中空部品と成形体との隙間に真空含浸する樹脂は、粘度(常温)が0.8Pa・sのエポキシ樹脂とした。
実施例1と同様な製造方法によって、コアである軟磁性体粉末の平均粒径が10nmのコアシェル型軟磁性体粉末を製造した。コアシェル型軟磁性体粉末の比率が45体積%となるように、コアシェル型軟磁性体粉末とエポキシ樹脂とを真空脱泡処理しながら混合した。次に、得られた混合物を直径2mm×長さ35mmの円柱形状に成形し、さらに樹脂を硬化させて成形体とした。
表1および表2に示すように、中空部品の筒状部の穴の直径R3を0.3mm、延長部の長さL2を0.7mmに変更すると共に、延長部の肉厚を0.2mmと厚くする以外は、実施例7と同様にしてアンテナ部品を作製した。中空部品と成形体との隙間に真空含浸する樹脂は、粘度(常温)が0.4Pa・sのエポキシ樹脂とした。
表1および表2に示すように、中空部品の筒状部の穴の直径R3を0.5mm、延長部の長さL2を1.2mmに変更すると共に、延長部の肉厚を0.2mmと厚くする以外は、実施例7と同様にしてアンテナ部品を作製した。中空部品と成形体との隙間に真空含浸する樹脂は、粘度(常温)が1Pa・sのエポキシ樹脂とした。
隔壁部に穴を形成していない中空部品を使用する以外は、実施例1と同様にしてアンテナ部品を作製した。
隔壁部の穴の直径R1を0.7mmと大きくした中空部品を使用する以外は、実施例1と同様にしてアンテナ部品を作製した。
Claims (20)
- 内側の寸法がR2の筒状部と、前記筒状部の一方の端部に設けられた隔壁部と、前記筒状部の他方の端部に設けられた開放部とを有する中空部品と、
前記中空部品内に挿入され、軟磁性を有する磁心材料と、
前記中空部品の外周に巻回されたコイルとを具備し、
前記隔壁部には、0.05mm≦R1≦0.5mm、R1<R2を満足する寸法R1を有する穴が設けられていることを特徴とするアンテナ部品。 - 請求項1記載のアンテナ部品において、
前記磁心材料は、軟磁性体粉末と樹脂との混合物の硬化体からなることを特徴とするアンテナ部品。 - 請求項2記載のアンテナ部品において、
前記軟磁性体粉末は、平均粒径が100nm以下のナノ金属粒子を有することを特徴とするアンテナ部品。 - 請求項1記載のアンテナ部品において、
前記穴の寸法R1は0.1mm≦R1≦0.35mmの範囲であることを特徴とするアンテナ部品。 - 請求項1記載のアンテナ部品において、
前記中空部品の側面には、0.05mm≦R3≦0.5mmの範囲の寸法R3を有する穴が設けられていることを特徴とするアンテナ部品。 - 請求項1記載のアンテナ部品において、
前記アンテナ部品の任意の断面において、前記中空部品の内面と前記磁心材料とが接触している領域が、前記中空部品の内周に対して50%以上であることを特徴とするアンテナ部品。 - 請求項1記載のアンテナ部品において、
前記隔壁部は、前記筒状部の最端部より内側に設けられていることを特徴とするアンテナ部品。 - 請求項1記載のアンテナ部品において、
前記中空部品と前記磁心材料との間の隙間に樹脂が充填されていることを特徴とするアンテナ部品。 - 請求項1記載のアンテナ部品において、
前記中空部品の前記筒状部は円筒形状を有し、前記筒状部の前記寸法R2は前記円筒形状の内径であることを特徴とするアンテナ部品。 - 請求項1記載のアンテナ部品において、
前記穴は略円形または略楕円形であり、前記寸法R1は前記略円形の直径または前記略楕円形の短径であることを特徴とするアンテナ部品。 - 内側の寸法がR2の筒状部と、前記筒状部の一方の端部に設けられた隔壁部と、前記筒状部の他方の端部に設けられた開放部とを有する中空部品を用意する工程と、
軟磁性体粉末と樹脂との混合物を、前記中空部品内に前記開放部から充填する工程と、
前記中空部品内に充填された前記混合物中の前記樹脂を硬化させる工程と、
前記中空部品の外周にコイルを巻回する工程とを具備し、
前記隔壁部には、0.05mm≦R1≦0.5mm、R1<R2を満足する寸法R1を有する穴が設けられていることを特徴とするアンテナ部品の製造方法。 - 請求項11記載のアンテナ部品の製造方法において、
前記軟磁性体粉末は、平均粒径が100nm以下のナノ金属粒子を有することを特徴とするアンテナ部品の製造方法。 - 請求項11記載のアンテナ部品の製造方法において、
前記中空部品の側面には、0.05mm≦R3≦0.5mmの範囲の寸法R3を有する穴が設けられていることを特徴とするアンテナ部品の製造方法。 - 請求項11記載のアンテナ部品の製造方法において、
前記樹脂の粘度は、室温で0.05Pa・s以上3Pa・s以下であることを特徴とするアンテナ部品の製造方法。 - 請求項11記載のアンテナ部品の製造方法において、
前記中空部品の前記筒状部は円筒形状を有し、前記筒状部の前記寸法R2は前記円筒形状の内径であり、
前記穴は略円形または略楕円形であり、前記寸法R1は前記略円形の直径または前記略楕円形の短径であることを特徴とするアンテナ部品の製造方法。 - 内側の寸法がR2の筒状部と、前記筒状部の一方の端部に設けられた隔壁部と、前記筒状部の他方の端部に設けられた開放部とを有する中空部品を用意する工程と、
軟磁性体粉末と第1の樹脂との混合物を成形および硬化させて成形体を得る工程と、
前記成形体を前記中空部品内に前記開放部から挿入する工程と、
前記中空部品と前記成形体との間の隙間に第2の樹脂を充填する工程と、
前記第2の樹脂を硬化させる工程と、
前記中空部品の外周にコイルを巻回する工程とを具備し、
前記隔壁部には、0.05mm≦R1≦0.5mm、R1<R2を満足する寸法R1を有する穴が設けられていることを特徴とするアンテナ部品の製造方法。 - 請求項16記載のアンテナ部品の製造方法において、
前記軟磁性体粉末は、平均粒径が100nm以下のナノ金属粒子を有することを特徴とするアンテナ部品の製造方法。 - 請求項16記載のアンテナ部品の製造方法において、
前記中空部品の側面には、0.05mm≦R3≦0.5mmの範囲の寸法R3を有する穴が設けられていることを特徴とするアンテナ部品の製造方法。 - 請求項16記載のアンテナ部品の製造方法において、
前記第2の樹脂の粘度は、室温で0.05Pa・s以上3Pa・s以下であることを特徴とするアンテナ部品の製造方法。 - 請求項16記載のアンテナ部品の製造方法において、
前記中空部品の前記筒状部は円筒形状を有し、前記筒状部の前記寸法R2は前記円筒形状の内径であり、
前記穴は略円形または略楕円形であり、前記寸法R1は前記略円形の直径または前記略楕円形の短径であることを特徴とするアンテナ部品の製造方法。
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US20210189278A1 (en) * | 2019-12-18 | 2021-06-24 | Eta Sa Manufacture Horlogère Suisse | Method for manufacturing a mechanical timepiece part provided with a magnetic functional area |
US11662690B2 (en) | 2019-12-18 | 2023-05-30 | Eta Sa Manufacture Horlogère Suisse | Method for manufacturing at least two mechanical parts |
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KR102091739B1 (ko) * | 2019-02-01 | 2020-03-20 | 주식회사 센서뷰 | 밀리미터파(mmWave) 대역용 전송선로 일체형 저손실 유연 곡면형 및 직각형 다중 포트 안테나 |
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US20210189278A1 (en) * | 2019-12-18 | 2021-06-24 | Eta Sa Manufacture Horlogère Suisse | Method for manufacturing a mechanical timepiece part provided with a magnetic functional area |
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US11662690B2 (en) | 2019-12-18 | 2023-05-30 | Eta Sa Manufacture Horlogère Suisse | Method for manufacturing at least two mechanical parts |
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JP5770108B2 (ja) | 2015-08-26 |
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CN102742076A (zh) | 2012-10-17 |
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