WO2017150301A1 - 磁性フィルムおよびコイルモジュール - Google Patents
磁性フィルムおよびコイルモジュール Download PDFInfo
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- WO2017150301A1 WO2017150301A1 PCT/JP2017/006601 JP2017006601W WO2017150301A1 WO 2017150301 A1 WO2017150301 A1 WO 2017150301A1 JP 2017006601 W JP2017006601 W JP 2017006601W WO 2017150301 A1 WO2017150301 A1 WO 2017150301A1
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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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
- B32B7/025—Electric or magnetic properties
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
- H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/28—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder dispersed or suspended in a bonding agent
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/34—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials non-metallic substances, e.g. ferrites
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/34—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials non-metallic substances, e.g. ferrites
- H01F1/36—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials non-metallic substances, e.g. ferrites in the form of particles
- H01F1/37—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials non-metallic substances, e.g. ferrites in the form of particles in a bonding agent
- H01F1/375—Flexible bodies
Definitions
- the present invention relates to a magnetic film and a coil module using the same.
- a position detection device that detects a position by moving a pen-type position indicator on a position detection plane is called a digitizer and is widely used as an input device for a computer.
- This position detection device includes a position detection flat plate and a circuit board disposed under the position detection flat board and having a loop coil formed on the surface of the board. Then, the position of the position indicator is detected by using electromagnetic induction whose frequency band generated by the position indicator and the loop coil is around 500 kHz.
- Patent Document 1 discloses a magnetic film laminated circuit board comprising a circuit board, a surface layer, and a magnetic layer containing soft magnetic particles in this order.
- NFC Near Field Communication, near field communication
- NFC uses a frequency band in a higher frequency region than the position indicator.
- wireless power transmission contactless power transmission
- the coil modules used for these wireless communication and wireless power transmission are designed so that the maximum characteristics can be obtained at a resonance frequency of 13.56 MHz or 6.78 MHz.
- the magnetic flux that converges around the loop coil becomes large, so that the magnetic flux easily leaks to other than the loop coil. If the magnetic flux leaks, it may interfere with a metal member (metal casing, battery, etc.) around the magnetic member and may have an adverse effect. For this reason, further improvement in magnetic shielding properties for preventing magnetic leakage is required.
- An object of the present invention is to provide a magnetic film capable of improving magnetic sealability and communication characteristics and a coil module using the same.
- the present invention [1] includes a first layer having a complex permeability real part at 10 MHz of 50 or more and a complex permeability imaginary part of less than 30, and a complex permeability at 10 MHz provided on the first layer.
- a magnetic film including a second layer having a real part of 50 or more and a complex permeability imaginary part of 30 or more is included.
- the present invention [2] includes the magnetic film according to [1], wherein the real part of the complex permeability of the second layer is larger than the real part of the complex permeability of the first layer.
- the present invention [3] includes the magnetic film according to [1] or [2], wherein the thickness of the second layer is thinner than the thickness of the first layer.
- This invention [4] contains the magnetic film as described in [3] whose ratio of the thickness of the said 2nd layer with respect to the thickness of the said 1st layer is 1/2 or less.
- the first layer includes the magnetic film according to any one of [1] to [4] containing soft magnetic particles and a resin.
- the first layer includes the magnetic film according to any one of [1] to [4], which is made of a sintered body of a soft magnetic oxide.
- the second layer includes the magnetic film according to any one of [1] to [6] containing soft magnetic particles and a resin.
- the present invention [8] is a coil module for wireless communication or wireless power transmission using a 13.56 MHz or 6.78 MHz frequency band, comprising a substrate and a coil pattern provided on one side in the thickness direction of the substrate. And a magnetic film according to any one of [1] to [7], provided on the one side in the thickness direction of the coil module so that the first layer and the coil pattern are opposed to each other. Includes a coil module.
- the magnetic film of the present invention can improve the magnetic shielding properties and communication characteristics of the coil module.
- the coil module of the present invention is excellent in magnetic shielding properties and communication characteristics.
- FIG. 1 shows a cross-sectional view of one embodiment of the magnetic film of the present invention.
- FIG. 2 shows a cross-sectional view of a coil module including the magnetic film of FIG.
- FIG. 3 is a schematic diagram for evaluating magnetic shielding properties in the examples.
- FIG. 4 is a schematic diagram for evaluating communication characteristics in the embodiment.
- the vertical direction of the paper is the vertical direction (thickness direction, first direction)
- the upper side of the paper is the upper side (one side in the thickness direction, the first direction)
- the lower side of the paper is the lower side (thickness direction).
- the direction of FIG. 1 is used as a reference.
- the magnetic film 10 has a film shape (including a sheet shape) having a predetermined thickness, and has a flat upper surface and a flat lower surface.
- the magnetic film 10 is, for example, one part such as a coil module 11 described later, that is, not the coil module 11. That is, the magnetic film 10 is a component for producing the coil module 11 and the like, does not include the coil substrate 4, includes the first layer 1 and the second layer 2 described later, and distributes the component alone for industrial use. It is a possible device.
- the magnetic film 10 includes a first layer 1 and a second layer 2 disposed on the upper surface (one surface) thereof.
- the magnetic film 10 includes a first layer 1 and a second layer 2.
- the first layer 1 has a film shape.
- the first layer 1 is a layer for improving the magnetic shielding properties and communication characteristics of the coil module 11 together with the second layer 2.
- the complex permeability real part ( ⁇ ′) at 10 MHz is 50 or more, preferably 70 or more, more preferably 80 or more, still more preferably 100 or more. 1000 or less, preferably 800 or less, more preferably 600 or less, and further preferably 300 or less.
- the complex magnetic permeability imaginary part ( ⁇ ′′) at 10 MHz is less than 30, preferably 20 or less, more preferably 15 or less, and for example, 0.01 or more, preferably 0. 1 or more.
- the complex permeability real part of the first layer 1 is larger than the complex permeability imaginary part of the first layer 1, and the difference between the complex permeability real part and the complex permeability imaginary part is, for example, 50 or more, preferably It is 100 or more, for example, 1000 or less, preferably 200 or less. By setting the difference within the above range, magnetic field leakage can be suppressed while maintaining communication characteristics.
- the complex permeability real part ⁇ ′ and the complex permeability imaginary part ⁇ ′′ of each layer are obtained using an impedance analyzer (manufactured by Agilent, “4294A”). It is measured by the one-turn method (frequency 10 MHz).
- the thickness of the first layer 1 is, for example, 10 ⁇ m or more, preferably 30 ⁇ m or more, more preferably 80 ⁇ m or more, and for example, 2000 ⁇ m or less, preferably 1500 ⁇ m or less, more preferably 1000 ⁇ m or less, even more preferably. Is 500 ⁇ m or less.
- the first layer 1 is formed in a film shape from, for example, a first magnetic composition containing soft magnetic particles and a resin.
- the first layer 1 is excellent in impact resistance, crack resistance and moldability by using soft magnetic particles and a resin together.
- the soft magnetic particles used for the first layer 1 have a large complex permeability real part ( ⁇ ′), but are made of a material having a small complex permeability imaginary part ( ⁇ ′′) (soft for low ⁇ ′′). Magnetic particles).
- Examples of the material of the soft magnetic particles for the first layer include magnetic stainless steel (Fe—Cr—Al—Si alloy), Fe—Si—Al alloy, Fe—Ni alloy, and silicon copper (Fe—Cu—). Si alloy), Fe-Si alloy, Fe-Si-B (-Cu-Nb) alloy, Fe-Si-Cr-Ni alloy, Fe-Si-Cr alloy, Fe-Si-Al-Ni-Cr alloy, ferrite Etc.
- the soft magnetic particles of the first layer 1 preferably have a coercive force in the easy magnetization direction of, for example, 2.1 (Oe) or more, preferably 2.5 (Oe) or more.
- Soft magnetic particles of 10 (Oe) or less, preferably 5.0 (Oe) or less, more preferably 3.5 (Oe) or less are used.
- the coercive force can be measured by, for example, a vibrating sample magnetometer.
- These soft magnetic particles can be used alone or in combination of two or more.
- Examples of the particle shape include a bulk shape, a flat shape (plate shape), and a needle shape.
- the bulk shape includes, for example, a spherical shape, a rectangular parallelepiped shape, a crushed shape, a round shape, an aggregate, or a deformed shape thereof. From the viewpoint of improving the real part of the complex permeability and improving the magnetic shielding properties, a flat shape is preferable.
- the flatness (flatness) of the soft magnetic particles of the first layer 1 is, for example, 8 or more, preferably 15 or more, for example, 500 or less, preferably 450 or less.
- the flatness is calculated, for example, as an aspect ratio obtained by dividing the average particle diameter of particles by the average thickness of soft magnetic particles.
- the average particle diameter (average value of the maximum length) of the soft magnetic particles of the first layer 1 is, for example, 3.5 ⁇ m or more, preferably 10 ⁇ m or more, more preferably 20 ⁇ m or more, and for example, 200 ⁇ m or less.
- the thickness is preferably 150 ⁇ m or less, more preferably 80 ⁇ m or less, and still more preferably 40 ⁇ m or less.
- the average thickness is, for example, 0.1 ⁇ m or more, preferably 0.2 ⁇ m or more, and for example, 3.0 ⁇ m or less, preferably 2.5 ⁇ m or less.
- the influence of the demagnetizing field due to the soft magnetic particles can be reduced, and as a result, the permeability and coercive force of the soft magnetic particles can be adjusted.
- soft magnetic particles classified using a sieve or the like may be used as necessary.
- the average particle diameter can be measured by, for example, a laser diffraction particle size distribution measuring apparatus, and the average thickness can be measured by, for example, a scanning electron microscope (SEM).
- the mass ratio of the soft magnetic particles in the first magnetic composition is a solid content ratio, for example, 60 mass% or more, preferably 80 mass% or more, more preferably 85 mass% or more, and for example, 98 % By mass or less, preferably 95% by mass or less.
- the volume ratio of the soft magnetic particles in the first magnetic composition is a solid content ratio, for example, 40% by volume or more, preferably 50% by volume or more, for example, 90% by volume or less, preferably 70% by volume. % Or less.
- the resin examples include a thermosetting resin and a thermoplastic resin.
- thermosetting resin examples include epoxy resins, phenol resins, melamine resins, thermosetting polyimide resins, unsaturated polyester resins, polyurethane resins, and silicone resins. From the viewpoint of adhesiveness, heat resistance, etc., preferably, an epoxy resin and a phenol resin are used, and more preferably, a combination of an epoxy resin and a phenol resin is used.
- the epoxy resin examples include bifunctional epoxy resins such as bisphenol A type epoxy resin, bisphenol F type epoxy resin, modified bisphenol A type epoxy resin, modified bisphenol F type epoxy resin, and biphenyl type epoxy resin, for example, phenol novolac type epoxy.
- bifunctional epoxy resins such as bisphenol A type epoxy resin, bisphenol F type epoxy resin, modified bisphenol A type epoxy resin, modified bisphenol F type epoxy resin, and biphenyl type epoxy resin, for example, phenol novolac type epoxy.
- polyfunctional epoxy resins having three or more functions such as resin, cresol novolac type epoxy resin, trishydroxyphenylmethane type epoxy resin, tetraphenylolethane type epoxy resin, and dicyclopentadiene type epoxy resin. These epoxy resins can be used alone or in combination of two or more.
- a trifunctional or higher polyfunctional epoxy resin more preferably a cresol novolac type epoxy resin.
- a cresol novolac type epoxy resin By using these epoxy resins, it is excellent in strength, film formability, adhesion between the first layer 1 and the second layer 2, and the like.
- the epoxy equivalent of the epoxy resin is, for example, 230 g / eq.
- the phenol resin is a thermosetting resin that serves as a curing agent for the epoxy resin.
- the above polyfunctional phenol resin is mentioned.
- These phenol resins can be used alone or in combination of two or more.
- a phenol biphenylene resin is mentioned.
- the hydroxyl group equivalent of the phenol resin is, for example, 230 g / eq.
- thermoplastic resin examples include acrylic resin, ethylene-vinyl acetate copolymer, polycarbonate resin, polyamide resin (6-nylon, 6,6-nylon, etc.), thermoplastic polyimide resin, saturated polyester resin (PET, PBT, etc.). ) And the like.
- acrylic resin is used.
- an acrylic resin for example, an acrylic polymer obtained by polymerizing one or two or more (meth) acrylic acid alkyl esters having a linear or branched alkyl group as a monomer component, and the like are polymerized.
- (meth) acryl means “acryl and / or methacryl”.
- alkyl group examples include methyl, ethyl, propyl, isopropyl, n-butyl, t-butyl, isobutyl, amyl, isoamyl, hexyl, heptyl, cyclohexyl, 2- Alkyl having 1 to 20 carbon atoms such as ethylhexyl group, octyl group, isooctyl group, nonyl group, isononyl group, decyl group, isodecyl group, undecyl group, lauryl group, tridecyl group, tetradecyl group, stearyl group, octadecyl group, dodecyl group Groups.
- an alkyl group having 1 to 6 carbon atoms is used.
- the acrylic polymer may be a copolymer of (meth) acrylic acid alkyl ester and other monomers.
- Other monomers include, for example, glycidyl group-containing monomers such as glycidyl acrylate and glycidyl methacrylate, for example, carboxyl group-containing monomers such as acrylic acid, for example, acid anhydride monomers such as maleic anhydride, for example, (meth) acrylic acid 2 -Hydroxyl group-containing monomers such as hydroxyethyl, for example, phosphonic acid group-containing monomers such as sulfonic acid group-containing monomers such as styrene sulfonic acid, for example, styrene monomers such as acrylonitrile.
- These monomers can be used alone or in combination of two or more.
- the weight average molecular weight of the acrylic resin is, for example, 1 ⁇ 10 5 or more, preferably 3 ⁇ 10 5 or more, and for example, 1 ⁇ 10 6 or less.
- a weight average molecular weight is measured based on a standard polystyrene conversion value by gel permeation chromatography (GPC).
- the content ratio of the resin in the first magnetic composition is a solid content ratio, for example, 2% by mass or more, preferably 5% by mass or more, and for example, 40% by mass or less, preferably 20% by mass or less. It is.
- the first magnetic composition preferably uses a thermosetting resin and a thermoplastic resin in combination. More preferably, the thermosetting resin contains an epoxy resin and a phenol resin, and the thermoplastic resin contains an acrylic resin.
- the thermosetting resin contains an epoxy resin and a phenol resin
- the thermoplastic resin contains an acrylic resin.
- the content ratio of the epoxy resin to the resin is, for example, 5% by mass or more, preferably 15% by mass or more, and for example, 50% by mass or less, preferably 35% by mass or less.
- the content rate of the phenol resin with respect to resin is 5 mass% or more, for example, Preferably, it is 15 mass% or more, for example, is 50 mass% or less, Preferably, it is 35 mass% or less.
- the content rate of the acrylic resin with respect to resin is 15 mass% or more, for example, Preferably, it is 35 mass% or more, for example, is 70 mass% or less, Preferably, it is 50 mass% or less.
- the first magnetic composition can contain additives in addition to the above.
- the additive include a thermosetting catalyst, a dispersant, and a rheology control agent.
- the thermosetting catalyst is a catalyst that accelerates the curing of the thermosetting resin by heating, and includes, for example, an imidazole compound, a triphenylphosphine compound, a triphenylborane compound, an amino group-containing compound, and an acid anhydride type. Compound etc. are mentioned. Preferably, an imidazole compound is used.
- imidazole compounds examples include 2-phenylimidazole (trade name; 2PZ), 2-ethyl-4-methylimidazole (trade name; 2E4MZ), 2-methylimidazole (trade name; 2MZ), and 2-undecylimidazole.
- (Trade name; C11Z) 2-phenyl-1H-imidazole 4,5-dimethanol (trade name; 2PHZ-PW), 2,4-diamino-6- (2′-methylimidazolyl (1) ′) ethyl-
- Examples include s-triazine / isocyanuric acid adduct (trade name: 2MAOK-PW) (all trade names are manufactured by Shikoku Kasei Co., Ltd.).
- thermosetting catalysts can be used alone or in combination of two or more.
- the content ratio of the thermosetting catalyst is a solid content ratio with respect to 100 parts by mass of the resin, for example, 0.1 parts by mass or more, preferably 0.5 parts by mass or more, and for example, 10 parts by mass or less.
- the amount is preferably 5 parts by mass or less.
- the content of the thermosetting catalyst in the first magnetic composition is a solid content, for example, 0.01% by mass or more, preferably 0.05% by mass or more, and for example, 1% by mass or less. Preferably, it is 0.5 mass% or less.
- dispersing agent examples include polyoxyalkylene alkyl ether phosphate ester and polyoxyalkylene alkyl phenyl ether phosphate ester.
- polyoxyalkylene alkyl ether phosphate ester is used.
- dispersant examples include HIPLAAD series (“ED-152”, “ED-153”, “ED-154”, “ED-118”, “ED-174”, “ED-174”, “ ED-251 ”) and the like.
- the acid value of the dispersant is, for example, 10 or more, preferably 15 or more, and for example, 200 or less, preferably 150 or less.
- the acid value is measured by a neutralization titration method or the like.
- the content of the dispersant is a solid content ratio with respect to 100 parts by mass of the soft magnetic particles, for example, 0.01 parts by mass or more, preferably 0.05 parts by mass or more, and for example, 1 part by mass. Hereinafter, it is preferably 0.5 parts by mass or less.
- the content rate of the dispersing agent in a 1st magnetic composition is 0.01 mass% or more, for example, Preferably, it is 0.05 mass% or more, for example, is 1 mass% or less, Preferably, it is 0.00. 5% by mass or less.
- the soft magnetic particles can be uniformly dispersed in the first layer 1. For this reason, the magnetic shielding properties and communication characteristics of the magnetic film 10 can be further improved.
- the rheology control agent is a compound that imparts a thixotropic property to the magnetic composition that exhibits a high viscosity when the shearing force (shear rate) is low and exhibits a low viscosity when the shearing force (shear rate) is high.
- rheology control agent examples include organic rheology control agents and inorganic rheology control agents.
- organic rheology control agent is used.
- organic rheology control agent examples include modified urea, urea-modified polyamide, fatty acid amide, polyurethane, and polymer urea derivative.
- Preferred examples include modified urea, urea-modified polyamide, and fatty acid amide, and more preferable examples include urea-modified polyamide.
- Examples of the inorganic rheology control agent include silica, calcium carbonate, smectite and the like.
- rheology control agent examples include “BYK-410”, “BYK-430”, “BYK-431” manufactured by BYK Chemie, and “Disparon PFA-131” manufactured by Enomoto Kasei. .
- rheology control agents can be used alone or in combination of two or more.
- the content ratio of the rheology control agent is, for example, 0.01 parts by mass or more, preferably 0.05 parts by mass or more, and, for example, 1 part by mass with respect to 100 parts by mass of the soft magnetic particles. Part or less, preferably 0.5 part by weight or less.
- the content ratio of the rheology control agent in the first magnetic composition is a solid content ratio, for example, 0.01% by mass or more, and preferably 0.05% by mass or more. For example, it is 1 mass% or less, Preferably, it is 0.5 mass% or less.
- the soft magnetic particles can be uniformly dispersed in the first layer 1 even when the soft magnetic particles are contained in the first layer 1 in a high proportion. Can do. For this reason, the magnetic shielding properties and communication characteristics of the magnetic film 10 can be further improved.
- the first magnetic composition can also contain other additives than the above.
- additives include commercially available or known additives such as a crosslinking agent and an inorganic filler.
- the second layer 2 has a film shape and is disposed on the entire upper surface of the first layer 1 so as to be in contact with the upper surface of the first layer 1.
- the second layer 2 is a layer for improving the magnetic shielding properties and communication characteristics of the coil module 11 together with the first layer 1.
- the complex magnetic permeability real part ( ⁇ ′) at 10 MHz is 50 or more, preferably 100 or more, more preferably 160 or more, and for example, 1500 or less, preferably 1000.
- more preferably 800 or less, and still more preferably 400 or less are examples of the complex magnetic permeability real part.
- the real part of the complex permeability of the second layer 2 is made larger than the real part of the complex permeability of the first layer 1.
- the difference between the real part of the complex permeability of the first layer 1 and the real part of the complex permeability of the second layer 2 is, for example, 10 or more, preferably 20 or more, more preferably 40 or more. 500 or less, preferably 300 or less.
- the complex permeability imaginary part of the second layer 2 can be more reliably made higher than the complex permeability imaginary part of the first layer 1, and the magnetic shielding properties can be improved more reliably.
- the complex permeability imaginary part ( ⁇ ′′) at 10 MHz is 30 or more, preferably 40 or more, more preferably 50 or more, and for example, 200 or less, preferably 150 or less, more Preferably, it is 100 or less, more preferably 80 or less.
- the complex permeability imaginary part of the second layer 2 is larger than the complex permeability imaginary part of the first layer 1.
- the difference between the complex permeability imaginary part of the first layer 1 and the second layer 2 is, for example, 10 or more, preferably 30 or more, and for example, 200 or less, preferably 80 or less.
- the complex permeability real part of the second layer 2 is preferably larger than the complex permeability imaginary part of the second layer 2, and the difference between the complex permeability real part and the complex permeability imaginary part is, for example, 50 or more, Preferably, it is 100 or more, for example, 1500 or less, preferably 500 or less. By making the difference within the above range, the magnetic shielding property in the second layer 2 becomes even better.
- the thickness of the second layer 2 is, for example, 1 ⁇ m or more, preferably 5 ⁇ m or more, and for example, 500 ⁇ m or less, preferably 300 ⁇ m or less, more preferably 60 ⁇ m or less.
- the thickness of the second layer 2 is thinner than the thickness of the first layer 1. More specifically, the ratio of the thickness of the second layer 2 to the thickness of the first layer 1 (second layer / first layer) is, for example, 1/2 or less, preferably 1/3 or less, more preferably , 1/4 or less, and for example, 1/10 or more. Thereby, both magnetic shielding properties and communication characteristics can be improved more reliably.
- the second layer 2 is made of, for example, a second magnetic composition containing soft magnetic particles and a resin. By containing the soft magnetic particles and the resin, the second layer 2 is excellent in impact resistance, crack resistance, and moldability.
- Soft magnetic particles used for the second layer 2 are particles made of a material having a large complex magnetic permeability real part ( ⁇ ′) and complex magnetic permeability imaginary part ( ⁇ ′′) (soft magnetic particles for high ⁇ ′′). ).
- Examples of the material of the soft magnetic particles for the second layer include Fe—Si—Al alloy, magnetic stainless steel (Fe—Cr—Al—Si alloy), Fe—Ni alloy, and silicon copper (Fe—Cu—). Si alloy), Fe-Si alloy, Fe-Si-B (-Cu-Nb) alloy, Fe-Si-Cr-Ni alloy, Fe-Si-Cr alloy, Fe-Si-Al-Ni-Cr alloy, etc. Can be mentioned. These soft magnetic particles can be used alone or in combination of two or more.
- the soft magnetic particles of the second layer 2 preferably have a coercive force in the easy magnetization direction of, for example, 0.1 (Oe) or more, preferably 0.3 (Oe) or more.
- Examples of the particle shape include a bulk shape, a flat shape (plate shape), and a needle shape.
- the bulk shape includes, for example, a spherical shape, a rectangular parallelepiped shape, a crushed shape, a round shape, an aggregate, or a deformed shape thereof. From the viewpoint of improving the real part of the complex permeability and improving the magnetic shielding properties, a flat shape is preferable.
- the flatness (flatness) of the soft magnetic particles of the second layer 2 is, for example, 8 or more, preferably 15 or more, and for example, 500 or less, preferably 450 or less.
- the average particle diameter (average value of the maximum length) of the soft magnetic particles of the second layer 2 is, for example, 3.5 ⁇ m or more, preferably 10 ⁇ m or more, more preferably more than 40 ⁇ m, and still more preferably 42 ⁇ m or more.
- it is 200 micrometers or less, Preferably, it is 150 micrometers or less, More preferably, it is 100 micrometers or less.
- the average thickness is, for example, 0.1 ⁇ m or more, preferably 0.2 ⁇ m or more, and for example, 3.0 ⁇ m or less, preferably 2.5 ⁇ m or less.
- the mass ratio of the soft magnetic particles in the second magnetic composition is a solid content ratio, for example, 60% by mass or more, preferably 80% by mass or more, more preferably 85% by mass or more. % By mass or less, preferably 95% by mass or less.
- the volume ratio of the soft magnetic particles in the second magnetic composition is a solid content ratio, for example, 40% by volume or more, preferably 50% by volume or more, for example, 90% by volume or less, preferably 70% by volume. % Or less.
- the resin examples include the same resins as those described above for the first layer 1.
- an epoxy resin, a phenol resin and an acrylic resin are used in combination.
- the blending ratio is the same as the blending ratio described above for the first layer 1.
- the second magnetic composition can contain additives.
- the additive include the same additives as those described above for the first layer.
- it contains a thermosetting catalyst, a dispersant and a rheology control agent.
- the blending ratio is the same as the blending ratio described above for the first layer 1.
- the second magnetic composition is formed of the same material as the first magnetic composition except that the first layer soft magnetic particles are changed to the second layer soft magnetic particles.
- the peeling by the difference in material etc. at the interface of the 1st layer 1 and the 2nd layer 2 can be prevented, and the durability of the magnetic shielding property and communication characteristic of the magnetic film 10 can be improved further.
- the magnetic film 10 includes, for example, a step of preparing a semi-cured first layer, a step of preparing a semi-cured second layer, and a step of laminating the semi-cured first layer and the semi-cured second layer and hot pressing. Can be manufactured.
- a semi-cured first layer is prepared.
- the first magnetic composition is dissolved or dispersed in a solvent to prepare a first magnetic composition solution, and then the first magnetic composition solution is applied to the surface of the release substrate and dried. .
- the first magnetic composition is prepared by mixing the above-described components in the above ratio.
- the solvent examples include ketones such as acetone and methyl ethyl ketone (MEK), esters such as ethyl acetate, ethers such as propylene glycol monomethyl ether, amides such as N, N-dimethylformamide, and the like.
- MEK methyl ethyl ketone
- esters such as ethyl acetate
- ethers such as propylene glycol monomethyl ether
- amides such as N, N-dimethylformamide, and the like.
- An organic solvent etc. are mentioned.
- the solvent also include aqueous solvents such as water, for example, alcohols such as methanol, ethanol, propanol, and isopropanol.
- the solid content in the first magnetic composition solution is, for example, 10% by mass or more, preferably 30% by mass or more, and for example, 90% by mass or less, preferably 70% by mass or less.
- the first magnetic composition solution is applied to the surface of the release substrate (separator, core material, etc.) and dried.
- Examples of the coating method include doctor blade coating, roll coating, screen coating, and gravure coating.
- the drying temperature is, for example, 50 ° C. or more and 150 ° C. or less (preferably 60 ° C. or more and 120 ° C. or less), and the drying time is, for example, 1 minute or more and 5 minutes or less.
- separator examples include a polyethylene terephthalate (PET) film, a polyethylene film, a polypropylene film, and paper. These are subjected to mold release treatment on the surface with, for example, a fluorine release agent, a long-chain alkyl acrylate release agent, a silicone release agent, or the like.
- PET polyethylene terephthalate
- a fluorine release agent for example, a fluorine release agent, a long-chain alkyl acrylate release agent, a silicone release agent, or the like.
- the core material examples include plastic films (eg, polyimide film, polyester film, polyethylene terephthalate film, polyethylene naphthalate film, polycarbonate film, etc.), metal films (eg, aluminum foil, etc.), such as glass fiber and plastic Examples include resin substrates reinforced with woven fibers, silicone substrates, glass substrates, and the like.
- plastic films eg, polyimide film, polyester film, polyethylene terephthalate film, polyethylene naphthalate film, polycarbonate film, etc.
- metal films eg, aluminum foil, etc.
- glass fiber and plastic examples include resin substrates reinforced with woven fibers, silicone substrates, glass substrates, and the like.
- the average thickness of the peeling substrate is, for example, 1 ⁇ m or more and 500 ⁇ m or less.
- the semi-cured state (B stage) is a state between an uncured state soluble in a solvent (A stage) and a completely cured state (C stage) at room temperature (25 ° C.), for example, Hardening and gelation progresses slightly, swells in a solvent but does not dissolve completely, softens by heating but does not melt.
- a semi-cured second layer is prepared.
- the second magnetic composition is dissolved or dispersed in a solvent to prepare a second magnetic composition solution, and then the second magnetic composition solution is applied to the surface of the release substrate and dried. .
- the second magnetic composition is prepared by mixing the above-described components at the above ratio.
- Solvent, coating / drying conditions, and the like are the same as those for preparing the semi-cured first layer.
- the semi-cured first layer and the semi-cured second layer 2 are laminated and hot pressed.
- a plurality of or a single semi-cured first layer and a plurality of or a single semi-cured second layer are laminated so that the semi-cured first layer and the semi-cured second layer have a predetermined thickness.
- a plurality (preferably 2 to 10) of semi-cured first layers and a single semi-cured second layer are laminated. .
- the semi-cured laminate is hot pressed in the thickness direction.
- the hot press can be performed using a known press machine, for example, a parallel plate press machine.
- a known press machine for example, a parallel plate press machine.
- the heating temperature is, for example, 130 ° C. or higher, preferably 150 ° C. or higher, and for example, 250 ° C. or lower, preferably 200 ° C. or lower.
- the hot press time is, for example, 1 minute or more, preferably 2 minutes or more, and for example, 24 hours or less, preferably 2 hours or less.
- the pressure is, for example, 0.1 MPa or more, preferably 1 MPa or more, more preferably 10 MPa or more, and for example, 200 MPa or less, preferably 100 MPa or less.
- each of the semi-cured first layer and the semi-cured second layer is heat-cured to be in a completely cured state (C stage), and at the same time, the semi-cured first layer and the semi-cured second layer are firmly adhered. As a result, the magnetic film 10 including the first layer 1 and the second layer 2 is obtained.
- the total thickness of the magnetic film 10 is, for example, 20 ⁇ m or more, preferably 50 ⁇ m or more, and for example, 2500 ⁇ m or less, preferably 500 ⁇ m or less, more preferably 200 ⁇ m or less.
- the coil module 11 includes a coil substrate 4, an adhesive layer 5, and a magnetic film 10 in order in the thickness direction.
- the coil module 11 preferably includes a coil substrate 4, an adhesive layer 5, and a magnetic film 10.
- the coil module 11 is one part such as a coil module for power reception used for wireless communication or wireless power transmission for wirelessly transmitting signals and power between power transmission / reception modules. Device.
- the coil substrate 4 is a circuit substrate used for wireless communication or wireless power transmission using a frequency band of 13.56 MHz or 6.78 MHz, for example, and includes a base substrate 6 as a substrate and a coil pattern 7.
- the base substrate 6 forms the outer shape of the coil module 11 and has a film shape.
- the insulating material constituting the base substrate 6 include a glass epoxy substrate, a glass substrate, a ceramic substrate, a PET substrate, a fluororesin substrate, and a polyimide substrate. From the viewpoint of flexibility, a PET substrate, a fluororesin substrate, a polyimide substrate and the like are preferable.
- the thickness of the base substrate 6 is, for example, 5 ⁇ m or more, preferably 8 ⁇ m or more, and for example, 100 ⁇ m or less, preferably 80 ⁇ m or less.
- the coil pattern 7 is provided on the upper side (one side in the thickness direction) of the base substrate 6. Specifically, the coil pattern 7 is disposed on the upper surface of the base substrate 6 so that the lower surface of the coil pattern 7 is in contact with the upper surface of the base substrate 6.
- the coil pattern 7 has one continuous wiring 8 formed in a spiral shape, and may be either circular (including an ellipse) or rectangular.
- Examples of the material constituting the wiring 8 include metals such as copper, nickel, tin, aluminum, iron, chromium, titanium, gold, silver, platinum, niobium, and alloys containing them, such as polyaniline, polypyrrole, and polythiophene. , Conductive polymers such as polyacetylene, polyparaphenylene, polyphenylene vinylene, polyacrylonitrile, and polyoxadiazole. These materials can be used alone or in combination of two or more.
- a metal is mentioned, More preferably, copper is mentioned.
- the width of the saddle wiring 8 is, for example, 10 ⁇ m or more, preferably 20 ⁇ m or more, and for example, 2000 ⁇ m or less, preferably 1800 ⁇ m or less.
- the gap (the pitch, the length of X shown in FIG. 2) of the saddle wiring 8 is, for example, 10 ⁇ m or more, preferably 20 ⁇ m or more, and, for example, 3 mm or less, preferably 2 mm or less.
- the thickness (height) of the saddle wiring 8 is, for example, 5 ⁇ m or more, preferably 8 ⁇ m or more, and for example, 100 ⁇ m or less, preferably 80 ⁇ m or less.
- the adhesive layer 5 is provided on the upper side of the coil substrate 4. Specifically, the adhesive layer 5 covers the side surface of the coil pattern 7 and is disposed between the base substrate 6 and the magnetic film 10 so as to contact the upper surface of the base substrate 6 and the lower surface of the magnetic film 10. .
- the adhesive layer 5 is formed from an adhesive composition into a film shape.
- the adhesive composition includes known or commercially available adhesives.
- the same resin and additive as the above-mentioned first magnetic composition can be used.
- Specific examples include an adhesive composition containing a resin and additives that are added as necessary.
- an adhesive composition containing a resin composed of an epoxy resin, a phenol resin, and an acrylic resin and a thermosetting catalyst is used.
- the thickness of the adhesive layer 5 is substantially the same as the thickness of the wiring 8 and is, for example, 5 ⁇ m or more, preferably 8 ⁇ m or more, and for example, 100 ⁇ m or less, preferably 80 ⁇ m or less.
- the magnetic film 10 is disposed on the upper surface of the coil pattern 7 and the upper surface of the adhesive layer 5 so that the first layer 1 is in contact with the upper surface of the coil pattern 7 and the upper surface of the adhesive layer 5.
- the coil module 11 is obtained, for example, by laminating the coil substrate 4, the semi-cured adhesive layer, and the magnetic film 10 and performing hot pressing.
- the semi-cured adhesive layer is prepared by dissolving or dispersing the adhesive composition in a solvent to prepare an adhesive composition solution, and subsequently applying the adhesive composition solution to the surface of the release substrate and drying. can get.
- a semi-cured adhesive layer can be prepared under the same conditions as the semi-cured first layer except for the raw material of the adhesive composition.
- the conditions of the hot press can be carried out under the same conditions as in the method for manufacturing the magnetic film 10.
- the upper surface of the coil pattern 7 is in direct contact with the lower surface of the first layer 1.
- the upper surface of the coil pattern 7 is directly in contact with the lower surface of the first layer 1. It may not be in contact. That is, the adhesive layer 5 is formed so that the thickness thereof is greater than the thickness of the coil pattern 7, and the first layer 1 may be disposed on the entire upper surface of the adhesive layer 5.
- the magnetic film 10 is disposed on the upper side of the coil substrate 4 with the adhesive layer 5 interposed therebetween.
- the magnetic film 10 can also be disposed on the surface.
- the coil module 11 includes a coil substrate 4 and a magnetic film 10 disposed on the upper surface thereof.
- the coil pattern 7 is buried in the first layer such that the upper surface and side surfaces of the coil pattern 7 are covered with the first layer 1. This embodiment is obtained, for example, by directly laminating the semi-cured first layer and the semi-cured second layer on the coil substrate 4 and performing hot pressing.
- the magnetic film 10 is disposed on the coil pattern 7 side of the coil substrate 4. Can also be arranged.
- the coil pattern 7 is formed only on the upper surface of the base substrate 6.
- the coil pattern 7 can be formed on the upper surface and the lower surface of the base substrate 6.
- it is excellent in magnetic shielding properties and communication characteristics.
- Interference can be reduced.
- the first layer 1 contains soft magnetic particles and a resin
- the second layer 2 contains soft magnetic particles and a resin.
- the coil module 11 including the magnetic film 10 can be used for a coil module for wireless communication or wireless power transmission using a frequency band of 13.56 MHz or 6.78 MHz, preferably NFC (Near Field Communication). ) Can be suitably used as a receiving coil module.
- Specific examples of products including such a coil module include non-contact IC cards and smartphones as wireless communication applications, and cordless phones, electric shavers, and electric motors as wireless power transmission applications. A toothbrush is mentioned.
- the first layer 1 is formed of the first magnetic composition containing soft magnetic particles and a resin.
- the first layer 1 is made of a soft magnetic oxide. It may be a layer made of a sintered body.
- the layer made of a sintered body of such a soft magnetic oxide is a layer obtained by sintering a metal oxide exhibiting soft magnetism (for example, a metal oxide containing Fe), and preferably And ferrite sheet. According to this embodiment, since the soft magnetic real part of the 1st layer 1 can be made still larger, it is excellent in magnetic shielding nature.
- the first layer 1 and the second layer 2 are in a completely cured state, but the first layer 1 and / or the second layer 2 may be in a semi-cured state.
- Example 1 (Preparation of the first layer)
- low ⁇ ′′ soft magnetic particles A (coercivity in the direction of easy magnetization: 3.9 (Oe) in terms of solid content so that the volume ratio of the soft magnetic particles is 60.0% by volume. ) 90.3 parts by mass, cresol novolac type epoxy resin 2.5 parts by mass, phenol biphenylene resin 2.6 parts by mass, acrylic resin 4.2 parts by mass, thermosetting catalyst 0.1 part by mass, dispersing agent 0.1 part by mass Part and 0.2 part by mass of the rheology control agent were mixed to obtain a first magnetic composition.
- This first magnetic composition was dissolved in methyl ethyl ketone to prepare a first magnetic composition solution having a solid content concentration of 41% by mass.
- the first magnetic composition solution was applied on a separator (PET film subjected to silicone release treatment), and then dried at 110 ° C. for 2 minutes. This produced the 1st layer (thickness 20 micrometers) of a semi-hardened state.
- a semi-cured second layer (thickness 20 ⁇ m) was prepared in the same manner as the first layer, except that the high ⁇ ′′ soft magnetic particles were used instead of the low ⁇ ′′ soft magnetic particles A.
- Example 2 In the first layer, instead of the soft magnetic particles A for low ⁇ ′′ (coercivity in the easy magnetization direction: 3.9 (Oe)), the soft magnetic particles B for low ⁇ ′′ (coercivity in the easy magnetization direction is 2). .9 (Oe)) was used to produce a magnetic film of Example 2 in the same manner as in Example 1.
- Example 3 A ferrite sheet (thickness: 100 ⁇ m) was prepared as the first layer, and the semi-cured second layer prepared in Example 1 was laminated on the ferrite sheet and hot pressed under the conditions of Example 1. Thereby, the magnetic film of Example 3 was manufactured.
- Example 4 A magnetic film of Example 4 was manufactured in the same manner as in Example 1 except that the thickness of the first layer was 50 ⁇ m and the thickness of the second layer was 70 ⁇ m.
- Comparative Example 1 Without using the semi-cured second layer, only six semi-cured first layers were stacked and hot pressed. Thereby, the magnetic body provided with only the first layer (thickness 120 ⁇ m) was used as the magnetic film of Comparative Example 1.
- Comparative Example 2 A ferrite sheet (thickness 120 ⁇ m) was prepared as the first layer, and only this sheet was used as the magnetic film of Comparative Example 2.
- Comparative Example 3 Instead of using the semi-cured first layer, only six semi-cured second layers were stacked and hot pressed. Thereby, the magnetic body provided with only the second layer (thickness 120 ⁇ m) was used as the magnetic film of Comparative Example 3.
- Comparative Example 4 (Preparation of the first layer)
- low ⁇ ′′ soft magnetic particles A (coercivity in the direction of easy magnetization: 3.9 (Oe) in terms of solid content so that the volume ratio of the soft magnetic particles is 30.0% by volume. ) 72.6 parts by weight, cresol novolac-type epoxy resin 7.3 parts by weight, phenol biphenylene resin 7.4 parts by weight, acrylic resin 12.3 parts by weight, thermosetting catalyst 0.3 part by weight, and dispersant 0.
- a first magnetic composition was obtained by mixing 1 part by mass.
- This first magnetic composition was dissolved in methyl ethyl ketone to prepare a first magnetic composition solution having a solid content concentration of 37% by mass.
- the first magnetic composition solution was applied on a separator (PET film subjected to silicone release treatment), and then dried at 110 ° C. for 2 minutes. This produced the 1st layer (thickness 20 micrometers) of a semi-hardened state.
- a semi-cured second layer was prepared in the same manner as the second layer of Example 1.
- the magnetic film of the comparative example 4 provided with the 1st layer (100 micrometers in thickness) and the 2nd layer (20 micrometers) was manufactured.
- Comparative Example 5 (Preparation of the first layer) A semi-cured first layer was prepared in the same manner as the first layer of Example 1.
- the magnetic film of the comparative example 5 provided with a 1st layer (thickness 100 micrometers) and a 2nd layer (20 micrometers) was manufactured.
- a coil substrate was prepared in which a rectangular loop coil was formed on the upper surface of a base substrate (made of polyimide, thickness 20 ⁇ m).
- the width of the wiring of the loop coil was 1000 ⁇ m
- the height of the wiring was 20 ⁇ m
- the distance X (pitch) between the wirings was 500 ⁇ m.
- an adhesive composition 18.7 parts by mass of a bisphenol A type epoxy resin, 6.9 parts by mass of a cresol novolac type epoxy resin, 28.2 parts by mass of a phenol biphenylene resin, 45.2 parts by mass of an acrylic resin, and a thermosetting catalyst 1.
- a semi-cured adhesive layer was prepared by mixing and drying 0 parts by mass.
- the magnetic film of each example and each comparative example is disposed on the coil substrate through the semi-cured adhesive layer so that the coil substrate and the first layer face each other, and subsequently, 175 ° C., 30 minutes, 0.
- the semi-cured adhesive layer was completely cured by hot pressing at 5 MPa.
- a coil module including a coil substrate, an adhesive layer, and a magnetic film in order was manufactured (see FIG. 2).
- Each coil module 11 is arranged on the upper surface of the mounting table 12 so that the magnetic film 10 is on the upper side, and then the magnetic field probe 13 and the coil module 11 are mounted at a height of 5 mm from the upper surface of the mounting table 12. It was moved horizontally so as to cross (see FIG. 3). Note that MP-10L manufactured by NEC Engineering Co., Ltd. was used as the magnetic field probe 13, and the current applied to the coil was 40 mA, 13.56 MHz. The magnetic field strength at this time was measured with a magnetic field probe.
- a coil substrate without an adhesive layer and a magnetic film was used as a reference coil module, and the magnetic field strength of the reference coil module was measured in the same manner as described above.
- the magnetic field strength of 3.5 dBuA / m or more is lower than the magnetic field strength of the reference coil module is evaluated as ⁇ , and the magnetic field strength of 2.5 dBuA / m or more and less than 3.5 dBuA / m. was evaluated as ⁇ , and when the magnetic field strength of less than 2.5 dBuA / m was decreased as x.
- Each coil module 11 is arranged on the upper surface of an aluminum plate 14 having a thickness of 1 mm so that the coil substrate 4 is on the upper side. Subsequently, the magnetic field probe 13 is placed at a position 4 cm high from the upper surface of the coil substrate 4. The module 11 was moved in the horizontal direction across the module 11 (see FIG. 4). Note that MP-10L manufactured by NEC Engineering Co., Ltd. was used as the magnetic field probe 13, and the current applied to the coil was 40 mA, 13.56 MHz. The magnetic field strength at this time was measured with a magnetic field probe.
- the case where the magnetic field radiation intensity was 10 dBuA / m or more higher than the magnetic field radiation intensity of the coil module of Comparative Example 3 was evaluated as ⁇ .
- a case where the magnetic field radiation intensity was higher than the magnetic field radiation intensity of the coil module of Comparative Example 3 in the range of 1 dBuA / m or more and less than 10 dBuA / m was evaluated as ⁇ .
- the case where the magnetic field radiation intensity and the magnetic field radiation intensity of the coil module of Comparative Example 3 were equal or less than each other was evaluated as x.
- Rheology control agent urea modified medium polarity polyamide, trade name “BYK430” (solid content 30% by mass), Made by Big Chemie Japan Co., Ltd.
- BYK430 solid content 30% by mass
- the magnetic film and coil module of the present invention can be applied to various industrial products, and can be suitably used for, for example, a coil module for wireless communication or wireless power transmission.
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Abstract
Description
(第1層の用意)
磁性組成物において、軟磁性粒子の体積割合が60.0体積%となるように、固形分換算で、低μ´´用軟磁性粒子A(磁化容易方向の保磁力:3.9(Oe))90.3質量部、クレゾールノボラック型エポキシ樹脂2.5質量部、フェノールビフェニレン樹脂2.6質量部、アクリル樹脂4.2質量部、熱硬化触媒0.1質量部、分散剤0.1質量部、および、レオロジーコントロール剤0.2質量部を混合することにより、第1磁性組成物を得た。
低μ´´用軟磁性粒子Aの代わりに高μ´´用軟磁性粒子を用いた以外は、第1層と同様にして、半硬化状態の第2層(厚み20μm)を作製した。
半硬化状態の第1層を5層用意し、半硬化状態の第2層を1層用意して、これらを第2層が最上面となるように積層した。積層体を175℃、30分、20MPaの条件で熱プレスすることにより、各層を完全硬化した。これにより、第1層(厚み100μm)および第2層(20μm)を備える磁性フィルムを製造した(図1参照)。
第1層において、低μ´´用軟磁性粒子A(磁化容易方向の保磁力:3.9(Oe))の代わりに低μ´´用軟磁性粒子B(磁化容易方向の保磁力が2.9(Oe))を用いた以外は、実施例1と同様にして、実施例2の磁性フィルムを製造した。
第1層としてフェライトシート(厚み100μm)を用意し、このフェライトシートに、実施例1で用意した半硬化状態の第2層を積層して、実施例1の条件で熱プレスした。これにより、実施例3の磁性フィルムを製造した。
第1層の厚みを50μmにし、かつ、第2層の厚みを70μmにした以外は、実施例1と同様にして、実施例4の磁性フィルムを製造した。
半硬化状態の第2層を用いずに、半硬化状態の第1層のみを6枚積層して熱プレスした。これにより、第1層(厚み120μm)のみを備える磁性体を、比較例1の磁性フィルムとした。
第1層としてフェライトシート(厚み120μm)を用意し、このシートのみを比較例2の磁性フィルムとした。
半硬化状態の第1層を用いずに、半硬化状態の第2層のみを6枚積層して熱プレスした。これにより、第2層(厚み120μm)のみを備える磁性体を、比較例3の磁性フィルムとした。
(第1層の用意)
磁性組成物において、軟磁性粒子の体積割合が30.0体積%となるように、固形分換算で、低μ´´用軟磁性粒子A(磁化容易方向の保磁力:3.9(Oe))72.6質量部、クレゾールノボラック型エポキシ樹脂7.3質量部、フェノールビフェニレン樹脂7.4質量部、アクリル樹脂12.3質量部、熱硬化触媒0.3質量部、および、分散剤0.1質量部を混合することにより、第1磁性組成物を得た。
実施例1の第2層と同様の方法にて、半硬化状態の第2層を用意した。
半硬化状態の第1層を5層用意した。一方、半硬化状態の第2層を、175℃、30分、20MPaの条件で熱プレスすることにより、硬化した第2層(20μm)を得た。
(第1層の用意)
実施例1の第1層と同様の方法にて、半硬化状態の第1層を用意した。
比較例4の第1層と同様の方法にて、半硬化状態の第2層を用意した。
半硬化状態の第1層を5層用意し、175℃、30分、20MPaの条件で熱プレスすることにより、硬化した第1層(100μm)を得た。
各実施例および各比較例の第1層および第2層のそれぞれについて、インピーダンスアナライザー(Agilent社製、「4294A」)を用いて、1ターン法(周波数10MHz)によって複素透磁率実部μ´および複素透磁率虚部μ´´を測定した。結果を表1に示す。
矩形状のループコイルがベース基板(ポリイミド製、厚み20μm)の上面に形成されたコイル基板を用意した。ループコイルの配線の幅は1000μm、配線の高さは20μm、配線間の間隔X(ピッチ)は500μmであった。
各コイルモジュール11を載置台12の上面に、磁性フィルム10が上側となるようにして配置し、続いて、載置台12の上面から高さ5mmの位置で、磁界プローブ13を、コイルモジュール11を横切るように水平方向に移動させた(図3参照)。なお、磁界プローブ13として、NECエンジニアリング社製のMP-10Lを用い、コイルへの印加電流は、40mA、13.56MHzとした。このときの磁界強度を磁界プローブによって測定した。
各コイルモジュール11を1mm厚のアルミニウム板14の上面に、コイル基板4が上側となるようにして配置し、続いて、コイル基板4の上面から高さ4cmの位置で、磁界プローブ13を、コイルモジュール11を横切るように水平方向に移動させた(図4参照)。なお、磁界プローブ13として、NECエンジニアリング社製のMP-10Lを用い、コイルへの印加電流は、40mA、13.56MHzとした。このときの磁界強度を磁界プローブによって測定した。
・低μ´´用軟磁性粒子A:Fe-Si-Al系合金、扁平状、平均粒子径40μm、平均厚み1μm、磁化容易方向の保磁力:3.9(Oe)、
・低μ´´用軟磁性粒子B:Fe-Si-Al系合金、扁平状、平均粒子径40μm、平均厚み1μm、磁化容易方向の保磁力:2.9(Oe)、
・高μ´´用軟磁性粒子:Fe-Si-Al系合金、扁平状、平均粒子径43μm、平均厚み1μm、磁化容易方向の保磁力:1.5(Oe)
・フェライトシート:(Fe,Ni,Cu,Zn)の酸化物の焼結体、厚み100μmと120μmのそれぞれを用意。
・クレゾールノボラック型エポキシ樹脂:エポキシ当量199g/eq.商品名「KI-3000-4」、東都化成社製
・フェノールビフェニレン樹脂:水酸基当量203g/eq.、商品名「MEH-7851SS」、明和化成社製
・アクリル樹脂:カルボキシ基およびヒドロキシ基変性のアクリル酸エチル-アクリル酸ブチル-アクリロニトリル共重合体、重量平均分子量900,000、商品名「テイサンレジン SG-70L」(樹脂含有割合12.5質量%)、ナガセケムテックス社製
・熱硬化触媒:2-フェニル-1H-イミダゾール4,5-ジメタノール、商品名「キュアゾール2PHZ-PW」、四国化成社製
・分散剤:ポリエーテルリン酸エステル、酸価17、商品名「HIPLAAD ED152」、楠本化成社製
・レオロジーコントロール剤:ウレア変性中極性ポリアマイド、商品名「BYK430」(固形分30質量%)、ビックケミージャパン社製
なお、上記発明は、本発明の例示の実施形態として提供したが、これは単なる例示に過ぎず、限定的に解釈してはならない。当該技術分野の当業者によって明らかな本発明の変形例は、後記請求の範囲に含まれる。
2 第2層
4 コイル基板
6 ベース基板
7 コイルパターン
10 磁性フィルム
11 コイルモジュール
Claims (8)
- 10MHzにおける複素透磁率実部が50以上であり、複素透磁率虚部が30未満である第1層と、
前記第1層の上に設けられ、10MHzにおける複素透磁率実部が50以上であり、複素透磁率虚部が30以上である第2層と
を備えることを特徴とする、磁性フィルム。 - 前記第2層の複素透磁率実部が、前記第1層の複素透磁率実部よりも大きいことを特徴とする、請求項1に記載の磁性フィルム。
- 前記第2層の厚みが、前記第1層の厚みよりも薄いことを特徴とする、請求項1に記載の磁性フィルム。
- 前記第1層の厚みに対する前記第2層の厚みの比が、1/2以下であることを特徴とする、請求項3に記載の磁性フィルム。
- 前記第1層が、軟磁性粒子および樹脂を含有することを特徴とする、請求項1に記載の磁性フィルム。
- 前記第1層が、軟磁性酸化物の焼結体からなることを特徴とする、請求項1に記載の磁性フィルム。
- 前記第2層が、軟磁性粒子と樹脂とを含有することを特徴とする、請求項1に記載の磁性フィルム。
- 13.56MHzまたは6.78MHzの周波数帯を用いる無線通信または無線電力伝送用のコイルモジュールであって、
基板、および、前記基板の厚み方向一方側に設けられるコイルパターンを備えるコイル基板と、
前記コイルモジュールの厚み方向一方側に、前記第1層と前記コイルパターンとが対向するように設けられる請求項1に記載の磁性フィルムと
を備えることを特徴とする、コイルモジュール。
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