WO2019235364A1 - 電波吸収積層フィルム、その製造方法、及びそれを含む素子 - Google Patents
電波吸収積層フィルム、その製造方法、及びそれを含む素子 Download PDFInfo
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- WO2019235364A1 WO2019235364A1 PCT/JP2019/021622 JP2019021622W WO2019235364A1 WO 2019235364 A1 WO2019235364 A1 WO 2019235364A1 JP 2019021622 W JP2019021622 W JP 2019021622W WO 2019235364 A1 WO2019235364 A1 WO 2019235364A1
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Definitions
- the present invention relates to a radio wave absorption laminated film that is excellent in transmission attenuation and reflection attenuation in the millimeter wave band and above on both the front surface and the back surface, and exhibits good radio wave absorption performance even when designed extremely thin, and a method for producing the film And an element including the film.
- radio waves in the high frequency band is spreading.
- expansion of the use of radio waves in a high frequency band may cause a malfunction or malfunction of an electronic device due to interference between electronic components.
- a method of absorbing unnecessary radio waves with a radio wave absorber is used.
- radio wave absorbers are used to reduce the influence of unnecessary radio waves that should not be received.
- various radio wave absorbers that can satisfactorily absorb radio waves in a high frequency band have been proposed.
- a radio wave absorbing sheet containing carbon nanocoils and a resin for example, Patent Document 1 is known.
- a radio wave in the 76 GHz band is used in an in-vehicle radar for detecting an inter-vehicle distance or the like.
- use of radio waves in a high frequency band of, for example, 100 GHz or more is expected to expand in various applications. For this reason, a radio wave absorber that can satisfactorily absorb radio waves in the 76 GHz band and higher frequency bands is desired.
- a radio wave absorber that can absorb radio waves satisfactorily in a wide range in a high frequency band includes, for example, a radio wave absorption layer including a magnetic crystal made of ⁇ -Fe 2 O 3 based iron oxide.
- Radio wave absorbers have been proposed (for example, Patent Document 2 and Non-Patent Documents 1 to 3).
- the thickness of the radio wave absorption layer is increased in order to achieve sufficient millimeter wave absorption, or a metal layer is formed on the base material layer having the radio wave absorption layer. It was required to be pasted.
- the radio wave absorbing layer is made thick, there are problems that the manufacturing cost of the radio wave absorber is increased and it is difficult to reduce the size of the device.
- the radio wave absorber having a configuration in which a metal layer is attached to a base material layer has the following problems.
- the radio wave absorber having such a configuration typically includes a radio wave absorption layer on one surface and a metal layer on the other surface.
- the radio wave absorber When a radio wave absorber having such a configuration is used to absorb unnecessary radio waves incident on an integrated circuit (RFIC) for processing a high frequency signal, the radio wave absorber is arranged so that the metal layer faces the RFIC. . By doing so, unnecessary radio waves transmitted from the radio wave absorbing layer side toward the metal layer side can be attenuated, and the incidence of unnecessary radio waves on the RFIC can be suppressed.
- noise emitted from the RFIC toward the surface (metal layer) opposite to the radio wave absorption layer of the radio wave absorber is totally reflected by the metal layer. As a result, the reflected noise may cause a malfunction or malfunction of the electronic device due to interference between the electronic components. For this reason, both the front and back surfaces have both transmission attenuation that attenuates transmitted radio waves and reflection attenuation that attenuates reflected radio waves.
- a film-like electromagnetic wave absorber that exhibits the following.
- the present invention is excellent in transmission attenuation and reflection attenuation in the millimeter wave band or more on each of the front surface and the back surface, and has excellent radio wave absorption performance even when designed extremely thin.
- An object is to provide an absorbent laminated film, a method for producing the film, and an element including the film.
- the central layer includes at least one metal layer.
- a first aspect of the present invention is a radio wave absorption laminated film having a radio wave absorption layer
- the radio wave absorption laminated film has a center layer, two base material layers, and two radio wave absorption layers,
- the central layer includes at least one metal layer;
- the two base material layers are laminated on both sides of the central layer;
- the radio wave absorption layer is laminated on the surface opposite to the center layer,
- the two base material layers may be the same or different, and the two radio wave absorption layers may be the same or different,
- a second aspect of the present invention is a method for producing a radio wave absorption laminated film according to the first aspect, (A1) forming the radio wave absorption layer on the base material layer to form a laminate of the radio wave absorption layer and the base material layer at least twice, obtaining at least two of the laminates; and (B1) A manufacturing method including laminating a surface of a base material layer of the laminate on each of both surfaces of the central layer.
- a third aspect of the present invention is a method for manufacturing a radio wave absorption laminated film according to the first aspect, (A2) including laminating the base material layer on both surfaces of the central layer; and (b2) forming a radio wave absorption layer on each of the two base material layers laminated on the central layer. It is a manufacturing method.
- 4th aspect of this invention is an element containing the electromagnetic wave absorption laminated film which concerns on a 1st aspect.
- the radio wave absorption laminated film according to the first aspect is excellent in transmission attenuation and reflection attenuation in the millimeter wave band or more on each of the front surface and the back surface, and exhibits excellent radio wave absorption performance even when designed extremely thin.
- the element containing the manufacturing method of the said electromagnetic wave absorption laminated film and the said electromagnetic wave absorption laminated film can be provided.
- FIG. 6 is a cross-sectional view of laminated films of Comparative Examples 1 to 3.
- FIG. It is a figure which shows the transmission attenuation amount and reflection attenuation amount in the millimeter wave frequency band of the electromagnetic wave absorption laminated film of Example 1.
- FIG. It is a figure which shows the transmission attenuation amount and reflection attenuation amount in the millimeter wave frequency band of the laminated film of the comparative example 1.
- FIG. It is a figure which shows the transmission attenuation amount and reflection attenuation amount in the millimeter wave frequency band of the laminated film of the comparative example 3.
- FIG. 1 is a cross-sectional view of a preferred embodiment of the radio wave absorption laminated film according to the first aspect.
- the electromagnetic wave absorption laminated film which concerns on a 1st aspect is demonstrated below.
- the radio wave absorption laminated film 1 is a radio wave absorption laminated film having a radio wave absorption layer 2,
- the radio wave absorption laminated film has a center layer 3, two base material layers 4, and two radio wave absorption layers 2,
- the central layer 3 comprises at least one metal layer;
- Two base material layers 4 are laminated on both sides of the center layer 3,
- the radio wave absorption layer 2 is laminated on the surface opposite to the center layer 3,
- the two base material layers 4 may be the same or different, and the two radio wave absorption layers 2 may be the same or different.
- At least one of the radio wave absorption layers 2 includes a magnetic material.
- the frequency band of 30 gigahertz (GHz) or higher from the viewpoint of more reliably absorbing high frequency radio waves of the millimeter wave band or higher for at least one side (preferably both sides) of the radio wave absorption laminated film according to the first aspect.
- a frequency band of 30 GHz to 300 GHz, more preferably a frequency band of 40 GHz to 200 GHz where the absolute value of the transmission attenuation is 10 decibels (dB) or more and the absolute value of the return loss is 10 dB or more.
- the absolute value of the transmission attenuation amount is 20 dB or more, and the absolute value of the reflection attenuation amount has a peak of 20 dB or more, and the absolute value of the transmission attenuation amount in a frequency band of 30 GHz or more. Is 20 dB or more and the return loss is in a frequency band of 50 GHz to 100 GHz. More preferably the absolute value has a higher peak 20 dB.
- the values of the transmission attenuation amount and the reflection attenuation amount are values measured under the conditions measured in Examples described later.
- the shape of the radio wave absorption laminated film may have a curved surface, may be composed of only a flat surface, and is preferably flat.
- the thickness of the radio wave absorption laminated film according to the first aspect is preferably 1000 ⁇ m or less, and 900 ⁇ m or less from the viewpoint of thinning or downsizing the film without impairing the effects of the present invention. Is more preferable, and it is still more preferable that it is 450 micrometers or less.
- the radio wave absorption layer 2 is laminated on the surface opposite to the center layer 3 for each of the two base material layers 4.
- the two radio wave absorption layers 2 may have the same configuration (composition, thickness, physical properties, etc.) or may be different.
- At least one of the radio wave absorption layers 2 includes a magnetic material. From the viewpoint of more reliably achieving the effects of the present invention, it is preferable that both of the radio wave absorption layers 2 include a magnetic material.
- the magnetic body is preferably a magnetic body that magnetically resonates in a frequency band of 30 GHz or more, and more preferably a magnetic body that resonates in a frequency band of 30 GHz or more and 300 GHz or less, from the viewpoint of being able to absorb high-frequency radio waves in the millimeter wave band or higher. preferable.
- magnétique resonance examples include magnetic resonance based on precession when electrons in an atom perform spin motion in a frequency band of a millimeter wave band or higher. Natural magnetic resonance based on a gyromagnetic effect based on precession in a frequency band above the millimeter wave band is preferable.
- the magnetic body is not particularly limited as long as it can absorb high-frequency radio waves in the millimeter wave band or higher.
- a preferable magnetic body includes a magnetic body including at least one selected from the group consisting of epsilon-type iron oxide, barium ferrite magnetic body, and strontium ferrite magnetic body. The epsilon type iron oxide will be described below.
- Epsilon iron oxide As epsilon type iron oxide, ⁇ -Fe 2 O 3 crystal, and crystal structure and space group are the same as ⁇ -Fe 2 O 3, and part of Fe site of ⁇ -Fe 2 O 3 crystal is Fe Selected from the group consisting of crystals represented by the formula ⁇ -M x Fe 2-x O 3 and wherein x is 0 or more and 2 or less (preferably 0 or more and less than 2) It is preferable that it is at least one kind. Since such an epsilon-type iron oxide crystal is a magnetic crystal, in the specification of the present application, the crystal may be referred to as a “magnetic crystal”.
- Any ⁇ -Fe 2 O 3 crystal can be used. It has the same crystal structure and space group as ⁇ -Fe 2 O 3, and in which a part of the Fe site of ⁇ -Fe 2 O 3 crystals is substituted by an element M other than Fe, wherein epsilon-M x A crystal represented by Fe 2-x O 3 and having x of 0 or more and 2 or less (preferably 0 or more and less than 2) will be described later.
- ⁇ -M x Fe 2-x O 3 in which part of the Fe site of the ⁇ -Fe 2 O 3 crystal is substituted with the substitution element M is also referred to as “M-substituted ⁇ -Fe 2 O 3 ”.
- the particle diameter of the particles having ⁇ -Fe 2 O 3 crystals and / or M-substituted ⁇ -Fe 2 O 3 crystals in the magnetic phase is not particularly limited as long as the object of the present invention is not impaired.
- particles having a magnetic phase of epsilon-type iron oxide magnetic crystals produced by a method as described later have an average particle diameter measured from a TEM (transmission electron microscope) photograph in the range of 5 nm to 200 nm. is there.
- the coefficient of variation (standard deviation of particle diameter / average particle diameter) of particles having magnetic layers of epsilon-type iron oxide magnetic crystals produced by the method described below is in the range of less than 80%, A group of fine particles with a uniform particle size.
- powder of such epsilon-type iron oxide magnetic particles that is, particles having ⁇ -Fe 2 O 3 crystals and / or M-substituted ⁇ -Fe 2 O 3 crystals in the magnetic phase.
- the “magnetic phase” referred to here is a portion responsible for the magnetism of the powder.
- “Having ⁇ -Fe 2 O 3 crystal and / or M-substituted ⁇ -Fe 2 O 3 crystal in the magnetic phase” means that the magnetic phase is ⁇ -Fe 2 O 3 crystal and / or M-substituted ⁇ -Fe 2 O 3 It means that it consists of crystals, and includes a case where impurity magnetic crystals that are unavoidable in production are mixed in the magnetic phase.
- the magnetic crystal of epsilon-type iron oxide is an iron oxide impurity crystal (specifically, ⁇ -Fe 2 O 3 , ⁇ -Fe 2 O, which has a space group or oxidation state different from that of ⁇ -Fe 2 O 3 crystal. 3 , FeO, and Fe 3 O 4 , and crystals in which part of Fe in these crystals is substituted with other elements.
- the magnetic crystal of epsilon-type iron oxide includes an impurity crystal
- the magnetic crystal of ⁇ -Fe 2 O 3 and / or M-substituted ⁇ -Fe 2 O 3 is preferably the main phase.
- the ratio of the magnetic crystals of ⁇ -Fe 2 O 3 and / or M-substituted ⁇ -Fe 2 O 3 is a molar ratio as a compound. What is 50 mol% or more is preferable.
- the abundance ratio of the crystals can be obtained by analysis by the Rietveld method based on the X-ray diffraction pattern.
- a nonmagnetic compound such as silica (SiO 2 ) formed in the sol-gel process may adhere around the magnetic phase.
- the type of the element M in the M-substituted ⁇ -Fe 2 O 3 is not particularly limited.
- the M-substituted ⁇ -Fe 2 O 3 may contain a plurality of elements M other than Fe.
- the element M include In, Ga, Al, Sc, Cr, Sm, Yb, Ce, Ru, Rh, Ti, Co, Ni, Mn, Zn, Zr, and Y. In these, In, Ga, Al, Ti, Co, and Rh are preferable.
- M is Al
- x is preferably in the range of 0 or more and less than 0.8, for example.
- M is Ga x is preferably in the range of 0 or more and less than 0.8, for example.
- M is In x is preferably in the range of 0 or more and less than 0.3, for example.
- M is Rh x is preferably in the range of, for example, 0 or more and less than 0.3.
- M is Ti and Co x is preferably in the range of 0 or more and less than 1, for example.
- the frequency that maximizes the amount of radio wave absorption can be adjusted by adjusting at least one of the type of element M and the amount of substitution in M-substituted ⁇ -Fe 2 O 3 .
- Such an M-substituted ⁇ -Fe 2 O 3 magnetic crystal can be synthesized, for example, by a process combining a reverse micelle method and a sol-gel method and a baking process, which will be described later. Further, an M-substituted ⁇ -Fe 2 O 3 magnetic crystal can be synthesized by a process combining a direct synthesis method and a sol-gel method and a firing process as disclosed in Japanese Patent Application Laid-Open No. 2008-174405. .
- M-substituted ⁇ -Fe 2 O 3 magnetic crystals can be obtained by a process combining a reverse micelle method and a sol-gel method and a firing process as described in the above.
- micelle solution I raw material micelle
- micelle solution II neutralizer micelle
- a silica coat is applied to the surface of the iron hydroxide fine particles formed in the micelle by a sol-gel method.
- the iron hydroxide fine particles provided with the silica coat layer are separated from the liquid, and then subjected to a heat treatment in an air atmosphere at a predetermined temperature (in the range of 700 to 1300 ° C.). By this heat treatment, fine particles of ⁇ -Fe 2 O 3 crystal are obtained.
- an M-substituted ⁇ -Fe 2 O 3 magnetic crystal is produced as follows.
- III Nine hydrate, in case of Ga, gallium nitrate (III) hydrate, in case of In, indium (III) nitrate trihydrate, in case of Ti and Co, hydration of titanium (IV) sulfate And cobalt (II) nitrate hexahydrate) and a surfactant (for example, cetyltrimethylammonium bromide) are dissolved.
- a surfactant for example, cetyltrimethylammonium bromide
- nitrate of alkaline earth metal Ba, Sr, Ca, etc.
- This nitrate functions as a shape control agent.
- alkaline earth metal is present in the liquid, finally, rod-shaped M-substituted ⁇ -Fe 2 O 3 magnetic crystal particles are obtained.
- particles of M-substituted ⁇ -Fe 2 O 3 magnetic crystals that are nearly spherical can be obtained.
- the alkaline earth metal added as a shape control agent may remain in the surface layer portion of the generated M-substituted ⁇ -Fe 2 O 3 magnetic crystal.
- An aqueous ammonia solution is used for the aqueous phase of micelle solution II having n-octane as the oil phase.
- the sol-gel method After mixing the micelle solutions I and II, apply the sol-gel method. That is, stirring is continued while dripping silane (for example, tetraethylorthosilane) into the mixed solution of micelle solution, and the formation reaction of iron hydroxide or iron hydroxide containing element M is advanced in the micelle. Thereby, the particle surface of the fine iron hydroxide precipitate produced in the micelle is coated with silica produced by hydrolysis of silane.
- silane for example, tetraethylorthosilane
- the particle powder obtained by separating, washing and drying the M-containing iron hydroxide particles coated with silica is charged into a furnace, and is 700 ° C. to 1300 ° C., preferably 900 ° C. in the air.
- the heat treatment (firing) is performed in the temperature range of 1200 ° C. or lower, more preferably 950 ° C. or higher and 1150 ° C. or lower.
- an oxidation reaction proceeds in the silica coating, and fine M element-containing iron hydroxide fine particles are changed to fine M-substituted ⁇ -Fe 2 O 3 particles.
- silica coat is not ⁇ -Fe 2 O 3 or ⁇ -Fe 2 O 3 crystals, but M-substituted ⁇ -Fe 2 O, which has the same space group as ⁇ -Fe 2 O 3. Contributes to the formation of the three crystals and acts to prevent sintering of the particles. Further, when an appropriate amount of alkaline earth metal coexists, the particle shape tends to grow into a rod shape.
- the M-substituted ⁇ -Fe 2 O 3 magnetic crystal is further obtained by a process combining the direct synthesis method and the sol-gel method and a firing process as disclosed in JP-A-2008-174405. It can be synthesized economically advantageously.
- a precursor made of iron hydroxide (some of which may be partially substituted with another element) is formed.
- a sol-gel method is applied to form a silica coating layer on the surface of the precursor particles.
- the silica-coated particles are separated from the liquid and then subjected to heat treatment (firing) at a predetermined temperature, fine particles of M-substituted ⁇ -Fe 2 O 3 magnetic crystals are obtained.
- iron oxide crystals that have different space groups and oxidation states from ⁇ -Fe 2 O 3 crystals may be generated.
- impurity crystals that have different space groups and oxidation states from ⁇ -Fe 2 O 3 crystals
- polymorphisms having a composition of Fe 2 O 3 and different crystal structures ⁇ -Fe 2 O 3 and ⁇ -Fe 2 O 3 are the most universal.
- Other iron oxides include FeO and Fe 3 O 4 .
- the inclusion of such an impurity crystal is not preferable in order to bring out the characteristics of the M-substituted ⁇ -Fe 2 O 3 crystal as high as possible, but is allowed as long as the effects of the present invention are not impaired.
- the coercive force H c of the M-substituted ⁇ -Fe 2 O 3 magnetic crystal varies depending on the amount of substitution by the substitution element M.
- the substitution amount by substitution element M in the M-substituted ⁇ -Fe 2 O 3 magnetic crystal it is possible to adjust the coercive force H c of M-substituted ⁇ -Fe 2 O 3 magnetic crystal.
- the substitution amount by substitution element M in the M-substituted ⁇ -Fe 2 O 3 magnetic crystal it is possible to adjust the coercive force H c of M-substituted ⁇ -Fe 2 O 3 magnetic crystal.
- the more amount of substitution increases, the coercive force H c of M-substituted ⁇ -Fe 2 O 3 magnetic crystal is lowered.
- the coercivity H c of the M-substituted ⁇ -Fe 2 O 3 magnetic crystal increases as the substitution amount increases.
- the substituent element M Ga, Al, In, Ti, Co and Rh are preferred .
- wave absorption amount of epsilon-type iron oxide is also shifted frequency of the peak with a maximum in the low frequency side or the higher frequency side. That is, the peak frequency of the radio wave absorption amount can be controlled by the substitution amount of the M element.
- the particle size of the epsilon-type iron oxide can be controlled, for example, by adjusting the heat treatment (firing) temperature in the above process.
- a TEM transmission electron microscope
- the average particle diameter of epsilon-type iron oxide is more preferably 10 nm or more, and more preferably 20 nm or more.
- the average particle diameter which is the number average particle diameter
- the average particle diameter is defined as the diameter of the long axis direction of the particles observed on the TEM image. Calculate the diameter.
- the number of particles to be measured when determining the average particle diameter is not particularly limited as long as it is a sufficiently large number for calculating the average value, but is preferably 300 or more.
- a silica coat coated on the surface of iron hydroxide fine particles by the sol-gel method may be present on the surface of the M-substituted ⁇ -Fe 2 O 3 magnetic crystal after heat treatment (firing).
- a non-magnetic compound such as silica
- the nonmagnetic compound include heat resistant compounds such as alumina and zirconia in addition to silica.
- the non-magnetic compound is silica, by weight of Si in M-substituted ⁇ -Fe 2 O 3 magnetic crystals, the mass of the substitution elements M in M-substituted ⁇ -Fe 2 O 3 magnetic crystal, the sum of the mass of Fe On the other hand, it is preferable that it is 100 mass% or less.
- Part or most of the silica adhering to the M-substituted ⁇ -Fe 2 O 3 magnetic crystal can be removed by dipping in an alkaline solution. The amount of silica adhered can be adjusted to an arbitrary amount by such a method.
- the content of the magnetic substance in the radio wave absorption layer 2 is not particularly limited as long as the object of the present invention is not impaired.
- the content of the magnetic substance is preferably 30% by mass or more, more preferably 40% by mass or more, particularly preferably 60% by mass or more, and preferably 60% by mass or more and 91% by mass or less with respect to the solid content mass of the radio wave absorption layer 2. Is most preferred.
- the relative dielectric constant of the radio wave absorbing layer 2 is not particularly limited, but is preferably 6.5 or more, 65 or less, more preferably 10 or more and 50 or less, and more preferably 15 or more and 30 or less. Further preferred.
- the method for adjusting the relative dielectric constant of the radio wave absorption layer 2 is not particularly limited. Examples of a method for adjusting the relative dielectric constant of each of the radio wave absorption layers 2 include a method in which the radio wave absorption layer 2 contains a dielectric powder and the content of the dielectric powder is adjusted.
- Suitable examples of dielectrics include barium titanate, strontium titanate, calcium titanate, magnesium titanate, bismuth titanate, zirconium titanate, zinc titanate, and titanium dioxide.
- the radio wave absorption layer 2 may contain a combination of a plurality of types of dielectric powder.
- the particle diameter of the dielectric powder used for adjusting the relative dielectric constant of the radio wave absorption layer 2 is not particularly limited as long as the object of the present invention is not impaired.
- the average particle size of the dielectric powder is preferably 1 nm to 100 nm, and more preferably 5 nm to 50 nm.
- the average particle diameter of the dielectric powder is the number average diameter of the primary particles of the dielectric powder observed by an electron microscope.
- the amount of dielectric powder used is not particularly limited as long as the relative dielectric constant of each radio wave absorption layer 2 is within a predetermined range.
- the amount of the dielectric powder used is preferably 0% by mass or more and 20% by mass or less, and more preferably 5% by mass or more and 10% by mass or less with respect to the solid content mass of each radio wave absorption layer 2.
- the dielectric constant can be adjusted by incorporating carbon nanotubes in the radio wave absorption layer 2.
- Carbon nanotubes may be used in combination with the above dielectric powder.
- the blending amount of the carbon nanotubes in the radio wave absorption layer 2 is not particularly limited as long as the relative dielectric constant of the radio wave absorption layer 2 is within the predetermined range. However, since carbon nanotubes are also conductive materials, if the amount of carbon nanotubes used is excessive, the radio wave absorption characteristics provided by the radio wave absorption layer 2 may be impaired.
- the amount of carbon nanotubes used is preferably 0% by mass or more and 20% by mass or less, and more preferably 1% by mass or more and 10% by mass or less with respect to the solid content mass of the radio wave absorption layer 2.
- the relative magnetic permeability of the radio wave absorbing layer 2 is not particularly limited, but is preferably 1.0 or more and 1.5 or less.
- the method for adjusting the relative permeability of the radio wave absorption layer 2 is not particularly limited. As described above, the method of adjusting the relative permeability of each of the radio wave absorption layers 2 includes a method of adjusting the amount of substitution by the substitution element M in the epsilon-type iron oxide, a method of adjusting the content of the magnetic substance in the radio wave absorption layer 2, and the like. Is mentioned.
- the radio wave absorption layer 2 may contain a polymer.
- the radio wave absorption layer 2 includes a polymer, components such as the magnetic material can be easily dispersed in a matrix made of the polymer.
- the kind of polymer is not particularly limited as long as the object of the present invention is not impaired and the radio wave absorption layer 2 can be formed.
- the polymer may be an elastic material such as an elastomer or rubber.
- the polymer may be a thermoplastic resin or a curable resin.
- the curable resin may be a photocurable resin or a thermosetting resin.
- thermoplastic resin examples include polyacetal resin, polyamide resin, polycarbonate resin, polyester resin (polybutylene terephthalate, polyethylene terephthalate, polyarylate, etc.), FR-AS resin, FR-ABS resin, AS Resin, ABS resin, polyphenylene oxide resin, polyphenylene sulfide resin, polysulfone resin, polyether sulfone resin, polyether ether ketone resin, fluorine resin, polyimide resin, polyamideimide resin, polyamide bismaleimide resin, polyetherimide resin, polybenzo Oxazole resin, polybenzothiazole resin, polybenzimidazole resin, BT resin, polymethylpentene, ultrahigh molecular weight polyethylene, FR-polypropylene, Loin resin (e.g., methyl cellulose, ethyl cellulose), (meth) acrylic resin (polymethyl methacrylate, etc.), and polystyrene, and the like.
- polyacetal resin e.
- the polymer is a thermosetting resin
- a thermosetting resin include a phenol resin, a melamine resin, an epoxy resin, and an alkyd resin.
- the photo-curable resin resins obtained by photo-curing monomers having unsaturated bonds such as various vinyl monomers and various (meth) acrylic acid esters can be used.
- Preferred examples when the polymer is an elastic material include olefin elastomers, styrene elastomers, polyamide elastomers, polyester elastomers, polyurethane elastomers, and the like.
- the content of the polymer is not particularly limited as long as the object of the present invention is not impaired. 5 mass% or more and 30 mass% or less are preferable with respect to the solid content mass of the electromagnetic wave absorption layer 2, and, as for content of a polymer, 10 mass% or more and 25 mass% or less are more preferable.
- the radio wave absorption layer 2 may contain a dispersant.
- the dispersant may be mixed uniformly with the magnetic material, polymer, and the like.
- the dispersant may be blended in the polymer.
- the magnetic substance, which has been previously treated with a dispersant, and a substance added to adjust the relative permittivity and relative permeability may be blended in the material constituting the radio wave absorption layer 2.
- the type of the dispersant is not particularly limited as long as the object of the present invention is not impaired.
- a dispersant can be selected from various dispersants conventionally used for dispersing various inorganic fine particles or organic fine particles.
- Suitable examples of the dispersing agent include silane coupling agents (for example, phenyltrimethoxysilane), titanate coupling agents, zirconate coupling agents, and aluminate coupling agents.
- the content of the dispersant is not particularly limited as long as the object of the present invention is not impaired.
- the content of the dispersant is preferably 0.1% by mass or more and 30% by mass or less, more preferably 1% by mass or more and 15% by mass or less, and more preferably 1% by mass or more and 10% by mass or less with respect to the solid content mass of each radio wave absorption layer 2 A mass% or less is particularly preferred.
- the radio wave absorbing layer 2 may contain various additives other than the above-mentioned components as long as the object of the present invention is not impaired.
- the additive that can be included in the radio wave absorption layer 2 include a colorant, an antioxidant, an ultraviolet absorber, a flame retardant, a flame retardant aid, a plasticizer, and a surfactant. These additives are used in consideration of the amount that they are conventionally used within the range not impairing the object of the present invention.
- each of the radio wave absorbing layers 2 may have a curved surface, may be composed of only a flat surface, and is preferably flat.
- the thickness of each of the two radio wave absorbing layers 2 is preferably 700 ⁇ m or less and more preferably 300 ⁇ m or less from the viewpoint of making the film thinner or smaller without impairing the effects of the present invention. Preferably, it is 150 micrometers or less, and it is especially preferable that it is 100 micrometers or less.
- a radio wave absorption layer forming paste As a method of forming a radio wave absorption layer, a radio wave absorption layer forming paste is particularly useful because it can be formed with high efficiency without any limitation on the thickness and a radio wave absorption layer can be directly formed on a base material layer.
- the method of forming using is preferable.
- the radio wave absorption layer forming paste preferably contains the magnetic material.
- the radio wave absorption layer forming paste may contain the substances, polymers, and other components added for adjusting the relative dielectric constant, the relative magnetic permeability, etc. described above for the radio wave absorption layer.
- the radio wave absorption layer forming paste includes a compound that is a precursor of the curable resin. In this case, the radio wave absorption layer forming paste contains a curing agent, a curing accelerator, a polymerization initiator, and the like as necessary.
- the radio wave absorption layer forming paste contains a photopolymerizable or thermopolymerizable compound
- the radio wave absorption layer can be formed by exposing or heating the coating film.
- the radio wave absorption layer forming paste preferably further contains a dispersion medium.
- a dispersion medium is not necessarily required.
- the dispersion medium water, an organic solvent, and an aqueous solution of an organic solvent can be used.
- an organic solvent is preferable because it easily dissolves an organic component and has a low latent heat of vaporization and can be easily removed by drying.
- the organic solvent used as the dispersion medium include N, N, N ′, N′-tetramethylurea (TMU), N-methyl-2-pyrrolidone (NMP), N, N-dimethylacetamide ( DMAc), N, N-dimethylisobutyramide, N, N-diethylacetamide, N, N-dimethylformamide (DMF), N, N-diethylformamide, N-methylcaprolactam, 1,3-dimethyl-2-imidazolide
- TMU N-methyl-2-pyrrolidone
- DMAc N-dimethylacetamide
- DMF N-dimethylformamide
- N-methylcaprolactam 1,3-dimethyl-2-imidazolide
- Non-polar (DMI) nitrogen-containing polar solvents such as pyridine; ketones such as diethyl ketone, methyl butyl ketone, dipropyl ketone, cyclohexanone; n-p
- the solid content concentration of the radio wave absorption layer forming paste is appropriately adjusted according to the method of applying the radio wave absorption layer forming paste, the thickness of the radio wave absorption layer, and the like.
- the solid content concentration of the radio wave absorption layer forming paste is preferably 3% by mass or more and 60% by mass or less, and more preferably 10% by mass or more and 50% by mass or less.
- the solid content concentration of the paste is a value calculated as the mass of the solid content, which is the sum of the mass of the component not dissolved in the dispersion medium and the mass of the component dissolved in the dispersion medium.
- the center layer 3 includes at least one metal layer from the viewpoint of blocking millimeter waves.
- money, platinum, those alloys, etc. is mentioned from a viewpoint of achieving the effect of this invention more reliably.
- the center layer 3 may or may not include a layer other than the metal layer.
- the layer other than the metal layer may be any layer as long as the effects of the present invention are not impaired, and examples thereof include an adhesive layer or an adhesive layer between the metal layer and the base material layer 4.
- the adhesive layer or pressure-sensitive adhesive layer include an acrylic pressure-sensitive adhesive layer, a rubber-based pressure-sensitive adhesive layer, a silicone-based pressure-sensitive adhesive layer, and a urethane-based pressure-sensitive adhesive layer.
- the shape of the center layer 3 may have a curved surface, may be composed of only a flat surface, and is preferably flat.
- the thickness of the center layer 3 is preferably 600 ⁇ m or less, more preferably 400 ⁇ m or less, and more preferably 100 ⁇ m or less from the viewpoint of thinning or downsizing the film without impairing the effects of the present invention. It is more preferable that the thickness is 50 ⁇ m or less.
- the two base material layers 4 are laminated on both surfaces of the center layer 3,
- the radio wave absorption layer 2 is laminated on the surface opposite to the center layer 3, and the two base material layers 4 have the same configuration (composition, thickness, physical properties, etc.). It may or may not be.
- the base material layer 4 may be a layer containing an arbitrary base material as long as the effects of the present invention are not impaired, and examples thereof include a layer containing a resin.
- PET polyethylene terephthalate
- PEN polyethylene naphthalate
- PMMA acrylic
- PC polycarbonate
- COP cycloolefin polymer
- PET is preferable because of excellent heat resistance and a good balance between dimensional stability and cost.
- each base material layer 4 may have a curved surface, may be composed of only a flat surface, and is preferably flat.
- the thickness of each of the two base material layers 4 is preferably 800 ⁇ m or less and more preferably 500 ⁇ m or less from the viewpoint of thinning or downsizing the film without impairing the effects of the present invention. Preferably, it is more preferably 300 ⁇ m or less, and particularly preferably 150 ⁇ m or less.
- the radio wave absorption laminated film according to the first aspect is a variety of elements (vehicle-mounted elements, high-frequency antennas) in various information communication systems such as mobile phones, wireless LANs, ETC systems, intelligent road traffic systems, automobile driving support road systems, and satellite broadcasting. It can be used as a radio wave absorption film used for a device etc.).
- the method for producing a radio wave absorption laminated film according to the second aspect is a method for producing the radio wave absorption laminated film according to the first aspect, (A1) forming the radio wave absorption layer on the base material layer to form a laminate of the radio wave absorption layer and the base material layer at least twice, obtaining at least two of the laminates; and (B1) including laminating the surface of the base material layer of the laminate on each of both surfaces of the central layer.
- the laminated layers are fixed at an arbitrary position of the radio wave absorption laminated film so that the layers constituting the radio wave absorption laminated film do not shift or peel off.
- a fixing method a method of sandwiching at least one portion of the outer peripheral portion of the radio wave absorption laminated film with a fixing member such as a clip, a method of fixing each layer constituting the radio wave absorption laminated film by penetrating a fixing tool such as a screw, Examples include a method of stitching an arbitrary position of the radio wave absorption laminated film.
- the laminating method is not particularly limited.
- a preferable laminating method there may be mentioned a method in which the radio wave absorption layer and the base material layer are bonded together using an adhesive or a pressure-sensitive adhesive as necessary.
- the radio wave absorption is performed by a known method such as extrusion molding, injection molding, press molding, etc., using a mixture of essential or optional components contained in the radio wave absorption layer. Layers can be manufactured.
- the base material layer may be used as an insert material, and the base material layer and the radio wave absorption layer may be integrated using a known insert molding method. While these methods have an advantage of high production efficiency, they have a disadvantage that it is difficult to manufacture a thin radio wave absorption layer having a thickness of less than 1 mm.
- the method for forming the radio wave absorption layer and the laminate of the base material layer by forming the radio wave absorption layer on the base material layer using the above-described radio wave absorption layer forming paste is not particularly limited in thickness. This is preferable in that the radio wave absorption layer can be formed with high efficiency and the radio wave absorption layer can be directly formed on the base material layer.
- the method of applying the radio wave absorption layer forming paste on the base material layer is not particularly limited as long as the radio wave absorption layer having a desired thickness can be formed. Examples of the coating method include a spray coating method, a dip coating method, a roll coating method, a curtain coating method, a spin coating method, a screen printing method, a doctor blade method, and an applicator method.
- the radio wave absorption layer can be formed by drying the coating film formed and removing the dispersion medium.
- the thickness of the coating film is appropriately adjusted so that the radio wave absorption layer obtained after drying has a desired thickness.
- the drying method is not particularly limited. For example, (1) a method of drying on a hot plate at a temperature of 80 ° C. or higher and 180 ° C. or lower, preferably 90 ° C. or higher and 160 ° C. or lower, for 1 minute or longer and 30 minutes or shorter; Examples include a method of leaving at room temperature for several hours to several days, and (3) a method of removing the solvent by placing it in a warm air heater or an infrared heater for several tens of minutes to several hours.
- the method for producing a radio wave absorption laminated film according to the third aspect is a method for producing the radio wave absorption laminated film according to the first aspect, (A2) including laminating the base material layer on both surfaces of the central layer; and (b2) forming a radio wave absorption layer on each of the two base material layers laminated on the central layer. .
- the laminating method is not particularly limited.
- a preferable laminating method there is a method in which the center layer and the base material layer are bonded together using an adhesive or a pressure-sensitive adhesive as necessary.
- the base material layer is produced by a known method such as extrusion molding, injection molding, or press molding, using a mixture composed of the components included in the base material layer. be able to.
- the center layer may be used as an insert material, and the center layer and the base material layer may be integrated using a known insert molding method.
- the method for applying the base material layer forming composition on the center layer is not particularly limited as long as a base material layer having a desired thickness can be formed.
- the coating method include a spray coating method, a dip coating method, a roll coating method, a curtain coating method, a spin coating method, a screen printing method, a doctor blade method, and an applicator method.
- the same method as the method described above in (a1) may be mentioned.
- Examples of the method of directly forming the radio wave absorption layer on the surface of the base material layer include a method of applying the radio wave absorption layer forming paste on the base material layer described above in (a1).
- the radio wave absorption layer is formed by applying a radio wave absorption layer forming paste containing the magnetic substance on the base material layer. It is preferable.
- the element according to the fourth aspect includes the radio wave absorption laminated film according to the first aspect.
- the element according to the fourth aspect includes various elements (vehicle-mounted elements, high-frequency antenna elements, etc.) in various information communication systems such as mobile phones, wireless LANs, ETC systems, intelligent road traffic systems, automobile driving support road systems, satellite broadcasting, etc. Is included).
- the in-vehicle element include an in-vehicle element for an automobile travel support road system such as an in-vehicle radar that detects information such as a distance between vehicles using a millimeter wave in a 76 GHz band.
- the high-frequency antenna element preferably further includes a receiving antenna unit. From the viewpoint of fulfilling the function as an antenna element without significantly reducing even radio waves directly incident on the receiving antenna unit, the high frequency antenna element provides radio wave absorption characteristics as a whole high frequency antenna element, while receiving antenna unit It is more preferable to include the radio wave absorption laminated film according to the first aspect so that the radio wave directly incident on the radio wave is not attenuated to such an extent that the high frequency antenna element cannot perform the desired operation.
- the radio wave absorption laminated film according to the first aspect covers the surface on which the receiving antenna portion is not placed, and the radio wave absorption laminated film is received by
- the receiving antenna unit is usually connected to other components by wiring.
- the high-frequency antenna element there is a configuration in which a terminal is provided at an arbitrary position on the surface of the high-frequency antenna element, and wiring that connects the terminal and the receiving antenna unit is provided.
- ⁇ -Ga 0.45 Fe 1.55 O 3 was used as epsilon-type iron oxide.
- the average particle size of the epsilon type iron oxide was 20 nm or more and 30 nm or less.
- the CNT a multi-walled carbon nanotube having a major diameter of 150 nm (trade name VGCF-H; manufactured by Showa Denko KK) was used.
- the dispersant phenyltrimethoxysilane was used.
- Ethyl cellulose was used as the resin.
- the PET film (thickness: 125 ⁇ m) was coated with the applicator using the above-mentioned radio wave absorption layer forming paste and then dried at 90 ° C. for 20 minutes and 130 ° C. for 20 minutes to form a 70 ⁇ m thick radio wave absorption layer on the PET film. At least six laminates (total thickness of about 200 ⁇ m) of the radio wave absorption layer and the base material layer shown in 2 (a) were obtained. One of the laminates was subjected to the transmission attenuation and reflection attenuation tests described below as a laminated film of Comparative Example 1.
- 2A is a cross-sectional view of the laminated film of Comparative Example 1.
- FIG. In Fig.2 (a) 12 shows an electromagnetic wave absorption layer and 14 shows a base material layer (PET film).
- FIG.2 (c) shows a radio wave absorption layer and 34 shows a base material layer (PET film).
- a laminate film of Comparative Example 2 (total thickness of about 220 ⁇ m) shown in FIG. 2B is formed by laminating an aluminum metal sheet having a thickness of 20 ⁇ m on a PET film using one of the laminates described later. Were subjected to transmission attenuation and reflection attenuation tests.
- 22 indicates a radio wave absorption layer
- 23 indicates a central layer (aluminum metal layer)
- 24 indicates a base material layer (PET film).
- the radio wave absorption laminated film 1 of Example 1 includes a metal layer that is a central layer 3, a PET film that is two base material layers 4, and two radio wave absorption layers 2.
- FIG. 3 is a diagram showing transmission attenuation and reflection attenuation in the frequency band of 30 GHz to 200 GHz of the radio wave absorption laminated film of Example 1.
- the absolute value is 10 dB or more in the frequency band of 30 GHz to 200 GHz with respect to the incident wave from any of the “up” and “down” directions shown in FIG. It turns out that it is good. This seems to be based on the absorption effect by the radio wave absorption layer and the blocking effect by the metal layer.
- the absolute value of the return loss with respect to the incident wave from any of the “upper” and “lower” directions shown in FIG. 1 is 10 dB or more in the frequency band of 30 GHz to 200 GHz. It can be seen that there is a peak. This is presumably because the reflected wave reflected by the metal layer is absorbed by the radio wave absorbing layer with respect to the incident wave from any of the above directions.
- FIG. 4 is a diagram showing the transmission attenuation amount and the reflection attenuation amount in the frequency band of 30 GHz to 200 GHz of the laminated film of Comparative Example 1.
- FIG. 4A it can be seen that almost no transmission attenuation is observed with respect to the incident wave from any of the “upper” and “lower” directions shown in FIG. This is considered to be based on the absorption of only one radio wave absorption layer.
- FIG. 4B the reflection attenuation with respect to the incident wave from the “down” direction is slightly observed, but the reflection attenuation with respect to the incident wave from the “down” direction shown in FIG. It can be seen that is hardly seen. This seems to be because there is no reflected wave by the metal layer and it is based on the absorption only on the surface of the radio wave absorption layer.
- FIG. 5 is a diagram showing the transmission attenuation amount and the reflection attenuation amount in the frequency band of 30 GHz to 200 GHz of the laminated film of Comparative Example 2.
- the transmission attenuation with respect to the incident wave from any of the “upper” and “lower” directions shown in FIG. 2 (b) is also an absolute value in the frequency band of 30 GHz to 200 GHz. Is 10 dB or more, which is found to be favorable. This seems to be due to the presence of the metal layer.
- the return loss with respect to the incident wave from the “up” direction shown in FIG. 2B has a peak with an absolute value of 10 dB or more in a frequency band of 30 GHz to 200 GHz.
- FIG. 6 is a diagram showing the transmission attenuation amount and the reflection attenuation amount in the frequency band of 30 GHz or more and 200 GHz or less of the laminated film of Comparative Example 3.
- FIG. 6 (a) compared with the laminated film of Comparative Example 1 in which almost no transmission attenuation is observed with respect to incident waves from any of the “upper” and “lower” directions, Although the laminated film has two radio wave absorption layers for incident waves from both the “upper” and “lower” directions shown in FIG. 2C, the transmission attenuation is improved. It can be seen that the effect of blocking the transmitted wave by the metal layer is not seen, and the transmission attenuation is insufficient. As shown in FIG.
- the return loss with respect to the incident wave from the “up” direction shown in FIG. 2C has a peak with an absolute value of 10 dB or more in a frequency band of 30 GHz to 200 GHz.
- the reflection attenuation amount with respect to the incident wave from the “down” direction has a small peak, and it can be seen that no peak with an absolute value of 10 dB or more is observed. It is presumed that this is based on the fact that the reflection attenuation by the surfaces of both radio wave absorption layers is observed, but the stability is lacking because it is not the reflection wave by the metal layer.
- the radio wave absorption laminated film of Example 1 has transmission attenuation characteristics and reflection attenuation characteristics with respect to incident waves from any of the “upper” and “lower” directions shown in FIG. It can be seen that even if the total thickness is 420 ⁇ m or less, a very thin design exhibits good radio wave absorption performance. On the other hand, it can be seen that the laminated films of Comparative Examples 1 and 3 are inferior in both transmission attenuation and reflection attenuation. In addition, although the laminated film of Comparative Example 2 has good transmission attenuation, the metal layer totally reflects the incident wave from the “down” direction shown in FIG. 2B. It can be seen that the return loss is not obtained.
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Abstract
Description
このような要求に応えるため、高周波数帯域の電波を良好に吸収できる電波吸収体が種々提案されている。具体例としては、例えば、カーボンナノコイル及び樹脂を含有する電波吸収シート(例えば、特許文献1)が知られている。
しかしながら、電波吸収層を厚くする場合、電波吸収体の製造コストアップと、デバイスの小型化が困難であることとの不具合がある。
また、基材層に金属層を貼り付ける構成の電波吸収体には、以下の問題がある。このような構成の電波吸収体は、典型的には、一方の面に電波吸収層を備え、他方の面に金属層を備える。高周波信号を処理するための集積回路(RFIC)に入射する不要な電波を吸収するためにかかる構成の電波吸収体が用いられる場合、金属層がRFICと対向するように電波吸収体が配置される。そうすることによって、電波吸収層側から金属層側に向かって透過する不要な電波を減衰させることができ、RFICへの不要な電波の入射を抑制できる。
しかし、この場合、RFICから電波吸収体の電波吸収層と反対側の面(金属層)に向かって発せられるノイズが金属層によって全反射してしまう。そうすると、反射したノイズによって、電子部品同士の干渉による電子機器の故障や誤動作等を招く懸念が生じる。
このような事情から、表面と裏面とのそれぞれにおいて、透過する電波を減衰させる透過減衰性と、反射する電波を減衰させる反射減衰性とを兼ね備え、かつ極薄く設計されても良好な電波吸収性能を示すフィルム状の電波吸収体が求められている。
前記電波吸収積層フィルムが、中心層と、2つの基材層と、2つの電波吸収層とを有し、
前記中心層が、少なくとも1つの金属層を含み、
2つの前記基材層が、前記中心層の両面に積層されており、
2つの前記基材層のそれぞれについて、前記中心層とは反対の面に前記電波吸収層が積層されており、
2つの前記基材層は同一であっても異なっていてもよく、2つの前記電波吸収層は同一であっても異なっていてもよく、
前記電波吸収層の少なくとも1つが磁性体を含む、電波吸収積層フィルムである。
(a1)前記基材層上に前記電波吸収層を形成して電波吸収層及び基材層の積層体を形成することを少なくとも2回行い、前記積層体を少なくとも2つ得ること、及び、
(b1)前記中心層の両面それぞれに、前記積層体の基材層の面を積層させることを含む製造方法である。
(a2)前記中心層の両面それぞれに、前記基材層を積層させること、及び
(b2)前記中心層に積層された2つの前記基材層上に、それぞれ電波吸収層を形成することを含む製造方法である。
また、本発明によれば、上記電波吸収積層フィルムの製造方法、及び上記電波吸収積層フィルムを含む素子を提供することができる。
また、本明細書において、「~」は特に断りがなければ以上から以下を表す。
図1は、第1の態様に係る電波吸収積層フィルムの好ましい1つの実施形態の断面図である。
図1を参照して、第1の態様に係る電波吸収積層フィルムについて以下説明する。
第1の態様に係る電波吸収積層フィルム1は、電波吸収層2を有する電波吸収積層フィルムであって、
前記電波吸収積層フィルムが、中心層3と、2つの基材層4と、2つの電波吸収層2とを有し、
中心層3が、少なくとも1つの金属層を含み、
2つの基材層4が、中心層3の両面に積層されており、
2つの基材層4のそれぞれについて、中心層3とは反対の面に電波吸収層2が積層されており、
2つの基材層4は同一であっても異なっていてもよく、2つの電波吸収層2は同一であっても異なっていてもよく、
電波吸収層2の少なくとも1つが磁性体を含む。
透過減衰量及び反射減衰量の値は、特に断らない限り、後記実施例で測定した条件により測定される値とする。
第1の態様に係る電波吸収積層フィルムの厚さは、本発明の効果を損なうことなく、該フィルムを薄くしたり小型化したりする観点から、1000μm以下であることが好ましく、900μm以下であることがより好ましく、450μm以下であることが更に好ましい。
第1の態様において、電波吸収層2は、2つの基材層4のそれぞれについて、中心層3とは反対の面に積層される。2つの電波吸収層2は、構成(組成、厚さ、物性等)が同一であっても異なっていてもよい。電波吸収層2の少なくとも1つが磁性体を含む。本発明の効果をより確実に達成する観点から、電波吸収層2の両方が磁性体を含むことが好ましい。
以下イプシロン型酸化鉄について説明する。
イプシロン型酸化鉄としては、ε-Fe2O3結晶、及び、結晶構造と空間群がε-Fe2O3と同じであって、ε-Fe2O3結晶のFeサイトの一部がFe以外の元素Mで置換されたものであり、式ε-MxFe2-xO3で表され、前記xが0以上2以下(好ましくは0以上2未満)である結晶よりなる群から選択される少なくとも1種であることが好ましい。このようなイプシロン型酸化鉄の結晶は磁性結晶であるため、本願の明細書では、その結晶について「磁性結晶」と呼ぶことがある。
なお、本願明細書においてε-Fe2O3結晶のFeサイトの一部が置換元素Mで置換されたε-MxFe2-xO3を「M置換ε-Fe2O3」とも呼ぶ。
また、後述するような方法で製造される、イプシロン型酸化鉄の磁性結晶を磁性層に持つ粒子の変動係数(粒子径の標準偏差/平均粒子径)は80%未満の範囲にあり、比較的微細で粒子径の整った粒子群である。
「ε-Fe2O3結晶及び/又はM置換ε-Fe2O3結晶を磁性相に持つ」とは、磁性相がε-Fe2O3結晶及び/又はM置換ε-Fe2O3結晶からなることを意味し、その磁性相に製造上不可避的な不純物磁性結晶が混在する場合を含む。
イプシロン型酸化鉄の磁性結晶が不純物結晶を含む場合、ε-Fe2O3及び/又はM置換ε-Fe2O3の磁性結晶が主相であることが好ましい。すなわち、当該電波吸収材料を構成するイプシロン鉄酸化物の磁性結晶の中で、ε-Fe2O3及び/又はM置換ε-Fe2O3の磁性結晶の割合が、化合物としてのモル比で50モル%以上であるものが好ましい。
結晶と空間群がε-Fe2O3と同じであって、ε-Fe2O3結晶のFeサイトの一部がFe以外の元素Mで置換されたものであるとの条件を満たす限り、M置換ε-Fe2O3における元素Mの種類は特に限定されない。M置換ε-Fe2O3は、Fe以外の元素Mを複数種含んでいてもよい。
Jian Jin,Shinichi Ohkoshi and Kazuhito Hashimoto,ADVANCED MATERIALS 2004,16,No.1、January 5,p.48-51、
Shin-ichi Ohkoshi,Shunsuke Sakurai,Jian Jin,Kazuhito Hashimoto,JOURNAL OF APPLIED PHYSICS,97,10K312(2005)、
Shunsuke Sakurai,Jian Jin,Kazuhito Hashimoto and Shinichi Ohkoshi,JOURNAL OF THE PHYSICAL SOCIETY OF JAPAN,Vol.74,No.7,July,2005、p.1946-1949、
Asuka Namai,Shunsuke Sakurai,Makoto Nakajima,Tohru Suemoto,Kazuyuki Matsumoto,Masahiro Goto,Shinya Sasaki,and Shinichi Ohkoshi,Journal of the American Chemical Society, Vol.131,p.1170-1173,2009.等に記載されるような、逆ミセル法とゾル-ゲル法を組み合わせた工程及び焼成工程により、M置換ε-Fe2O3磁性結晶を得ることができる。
この熱処理によりシリカコーティング内で酸化反応が進行して、微細なM元素含有水酸化鉄の微細な粒子が、微細なM置換ε-Fe2O3の粒子に変化する。
このような不純物結晶の含有は、M置換ε-Fe2O3結晶の特性をできるだけ高く引き出す上で好ましいとは言えないが、本発明の効果を阻害しない範囲で許容される。
具体的には、例えばAl、Ga等を置換元素Mとして用いた場合には、置換量が増えるほど、M置換ε-Fe2O3磁性結晶の保磁力Hcが低下する。一方、Rh等を置換元素Mとして用いた場合には、置換量が増えるほど、M置換ε-Fe2O3磁性結晶の保磁力Hcは増大する。
置換元素Mによる置換量に応じてM置換ε-Fe2O3磁性結晶の保磁力Hcを調整しやすい点からは、置換元素Mとして、Ga、Al、In、Ti、Co及びRhが好ましい。
前述の逆ミセル法とゾル-ゲル法を組み合わせた手法や、特開2008-174405号公報に開示される直接合成法とゾル-ゲル法を組み合わせた手法によれば、TEM(透過型電子顕微鏡)写真から計測される平均粒子径として、5nm以上200nm以下の範囲の粒子径を有するイプシロン型酸化鉄の粒子を合成することが可能である。イプシロン型酸化鉄の平均粒子径は、10nm以上がより好ましく、20nm以上がより好ましい。
なお、数平均粒子径である平均粒子径を求める際、イプシロン型酸化鉄の粒子がロッド状である場合、TEM画像上で観察される粒子の長軸方向の径を当該粒子の径として平均粒子径を算出する。平均粒子径を求める際の、計測対象の粒子数は平均値を算出に当たり十分に多い数であれば特に限定されないが、300個以上であることが好ましい。
非磁性化合物の好適な例としては、シリカのほか、アルミナやジルコニア等の耐熱性化合物が挙げられる。
非磁性化合物がシリカである場合、M置換ε-Fe2O3磁性結晶におけるSiの質量は、M置換ε-Fe2O3磁性結晶における置換元素Mの質量と、Feの質量との合計に対して、100質量%以下であることが好ましい。
M置換ε-Fe2O3磁性結晶に付着したシリカの一部又は大部分は、アルカリ溶液に浸す方法によって除去できる。シリカ付着量はこのような方法で任意の量に調整可能である。
電波吸収層2は、その比誘電率としては特に制限はないがが、6.5以上65以下であることが好ましく、10以上50以下であることがより好ましく、15以上30以下であることが更に好ましい。電波吸収層2の比誘電率を調整する方法は特に限定されない。電波吸収層2各々の比誘電率の調整方法としては、電波吸収層2に誘電体の粉末を含有させ、且つ、誘電体の粉末の含有量を調整する方法が挙げられる。
カーボンナノチューブの使用量は、電波吸収層2の固形分質量に対して、0質量%以上20質量%以下が好ましく、1質量%以上10質量%以下がより好ましい。
電波吸収層2の比透磁率は特に限定されないが、1.0以上1.5以下が好ましい。電波吸収層2の比透磁率を調整する方法は特に限定されない。電波吸収層2各々の比透磁率の調整方法としては、前述の通り、イプシロン型酸化鉄における置換元素Mによる置換量を調整する方法、電波吸収層2における磁性体の含有量を調整する方法等が挙げられる。
上記磁性体等を電波吸収層2中に均一に分散させるとともに、厚さが均一な電波吸収層2の形成を容易にするために、電波吸収層2はポリマーを含んでいてもよい。電波吸収層2がポリマーを含む場合、ポリマーからなるマトリックス中に、上記磁性体等の成分を容易に分散させることができる。
上記磁性体、比誘電率及び比透磁率を調整するために添加される物質を電波吸収層2中で良好に分散させる目的で、電波吸収層2は分散剤を含んでいてもよい。分散剤は、上記磁性体、ポリマー等とともに均一に混合されてもよい。電波吸収層2がポリマーを含む場合、分散剤はポリマー中に配合されてもよい。また、分散剤により予め処理された、上記磁性体、比誘電率及び比透磁率を調整するために添加される物質を、電波吸収層2を構成する材料に配合してもよい。
電波吸収層2は、本発明の目的を阻害しない範囲で、上記の成分以外の種々の添加剤を含んでいてもよい。電波吸収層2が含み得る添加剤としては、着色剤、酸化防止剤、紫外線吸収剤、難燃剤、難燃助剤、可塑剤、及び界面活性剤等が挙げられる。これらの添加剤は、本発明の目的を阻害しない範囲で、それらが従来使用される量を勘案して使用される。
2つの電波吸収層2各々の厚さとしては、本発明の効果を損なうことなく、該フィルムを薄くしたり小型化したりする観点から、700μm以下であることが好ましく、300μm以下であることがより好ましく、150μm以下であることが更に好ましく、100μm以下であることが特に好ましい。
電波吸収層2各々の厚さの下限値としては本発明の効果を損なわない限り特に制限はないが、例えば、1μm以上、10μm以上、50μm以上等が挙げられる。
電波吸収層を形成する方法としては、特に厚さの制限なく高効率で電波吸収層を形成できる点と、基材層上に直接電波吸収層を形成できる点とから、電波吸収層形成用ペーストを用いて形成する方法が好ましい。
電波吸収層形成用ペーストは、上記磁性体を含有することが好ましい。電波吸収層形成用ペーストは、電波吸収層について前述した、比誘電率、比透磁率等の調整のために添加される物質、ポリマー及びその他の成分等を含有していてもよい。なお、ポリマーが硬化性樹脂である場合、電波吸収層形成用ペーストは、硬化性樹脂の前駆体である化合物を含む。この場合、電波吸収層形成用ペーストは、硬化剤、硬化促進剤、及び重合開始剤等を必要に応じて含有する。
第1の態様において、中心層3の両面に2つの基材層4が積層される。中心層3は、ミリ波を遮断する観点から、少なくとも1つの金属層を含む。
上記金属層としては、本発明の効果をより確実に達成する観点から、アルミニウム、チタン、SUS、銅、真鍮、銀、金、白金、ないしそれらの合金等を含む層が挙げられる。
上記金属層以外の層としては本発明の効果を損なわない限り任意の層であってよく、上記金属層と基材層4との間の接着層ないし粘着層等が挙げられる。上記接着層ないし粘着層としては、アクリル系粘着剤層、ゴム系粘着剤層、シリコーン系粘着剤層、ウレタン系粘着剤層等が挙げられる。
中心層3の厚さとしては、本発明の効果を損なうことなく、該フィルムを薄くしたり小型化したりする観点から、600μm以下であることが好ましく、400μm以下であることがより好ましく、100μm以下であることが更に好ましく、50μm以下であることが特に好ましい。
中心層3の厚さの下限値としては本発明の効果を損なわない限り特に制限はないが、例えば、1μm以上、5μm以上、10μm以上等が挙げられる。
第1の態様において、2つの基材層4は中心層3の両面に積層されており、
2つの基材層4のそれぞれについて、中心層3とは反対の面に電波吸収層2が積層されており、2つの基材層4は、構成(組成、厚さ、物性等)が同一であっても異なっていてもよい。
基材層4としては、本発明の効果を損なわない限り任意の基材を含む層であってよいが、例えば、樹脂を含む層等が挙げられる。
上記樹脂としては、例えば、ポリエチレンテレフタレート(PET)、ポリエチレンナフタレート(PEN)、アクリル(PMMA)、ポリカーボネート(PC)、シクロオレフィンポリマー(COP)、ポリエーテルスルフォン、ポリイミド、ポリアミドイミド等が挙げられる。なかでも、耐熱性に優れ、寸法安定性とコストとのバランスがよいことからPETが好ましい。
2つの基材層4各々の厚さとしては、本発明の効果を損なうことなく、該フィルムを薄くしたり小型化したりする観点から、800μm以下であることが好ましく、500μm以下であることがより好ましく、300μm以下であることが更に好ましく、150μm以下であることが特に好ましい。
基材層4各々の厚さの下限値としては本発明の効果を損なわない限り特に制限はないが、例えば、1μm以上、10μm以上、50μm以上等が挙げられる。
第1の態様に係る電波吸収積層フィルムは、携帯電話、無線LAN、ETCシステム、高度道路交通システム、自動車走行支援道路システム、衛星放送等の種々の情報通信システムにおける各種素子(車載素子、高周波アンテナ素子等を含む。)に用いられる電波吸収フィルムとして使用し得る。
<第2の態様に係る製造方法>
第2の態様に係る電波吸収積層フィルムの製造方法は、第1の態様に係る電波吸収積層フィルムの製造方法であって、
(a1)前記基材層上に前記電波吸収層を形成して電波吸収層及び基材層の積層体を形成することを少なくとも2回行い、前記積層体を少なくとも2つ得ること、及び、
(b1)前記中心層の両面それぞれに、前記積層体の基材層の面を積層させることを含む。
基材層上に前記電波吸収層を形成することを行い電波吸収層及び基材層の積層体を形成する方法としては特に制限はなく、基材層と、電波吸収層とを別個に形成した後に両者を積層してもよく、基材層の表面に直接電波吸収層を形成してもよい。
ここで、本願明細書における2つの層の積層は、2つの層が、外力により容易に剥離しない状態で接合された状態のみならず、2つの層が、外力により容易にずれたり剥離したりし得る状態で単に重ね合わせられた状態も含む。
積層状態が後者の状態である場合、電波吸収積層フィルムを構成する各層のずれや剥離が生じないように、電波吸収積層フィルムの任意の位置において、積層された各層が固定されることが好ましい。
固定方法としては、電波吸収積層フィルムの外周部の少なくとも1箇所をクリップ等の固定部材により挟持する方法、ビス等の固定具を貫通させることにより電波吸収積層フィルムを構成する各層を固定する方法、電波吸収積層フィルムの任意の位置を縫合する方法等が挙げられる。
これらの方法には、生産効率が高いメリットがある一方で、厚さが1mm未満である薄い電波吸収層の製造が困難であるデメリットがある。
基材層上に電波吸収層形成用ペーストを塗布する方法は、所望する厚さの電波吸収層を形成できる限り特に限定されない。塗布方法としては、例えば、スプレーコート法、ディップコート法、ロールコート法、カーテンコート法、スピンコート法、スクリーン印刷法、ドクターブレード法、及びアプリケーター法等が挙げられる。
上記の方法により、形成される塗布膜を乾燥させて分散媒を除去することで電波吸収層を形成することができる。塗布膜の膜厚は、乾燥後に得られる電波吸収層の厚さが所望の厚さになるように適宜調整される。
乾燥方法は、特に限定されず、例えば、(1)ホットプレートにて80℃以上180℃以下、好ましくは90℃以上160℃以下の温度にて1分間以上30分間以下乾燥させる方法、(2)室温にて数時間~数日間放置する方法、(3)温風ヒータや赤外線ヒータ中に数十分間~数時間入れて溶剤を除去する方法などが挙げられる。
前記中心層の両面それぞれに、電波吸収層及び基材層の積層体の基材層の面を積層させる方法としては特に制限はない。積層方法としては、中心層の両面それぞれと、基材層の面とを接合させる方法が挙げられる。接合方法として特に制限はない。好ましい接合方法としては、中心層それぞれの面と、基材層の面とを必要に応じて接着剤ないし粘着剤を用いて貼りあわせる方法が挙げられる。
第3の態様に係る電波吸収積層フィルムの製造方法は、第1の態様に係る電波吸収積層フィルムの製造方法であって、
(a2)前記中心層の両面それぞれに、前記基材層を積層させること、及び
(b2)前記中心層に積層された2つの前記基材層上に、それぞれ電波吸収層を形成することを含む。
中心層の両面それぞれに、基材層を積層させる方法としては特に制限はない。積層方法において、例えば、中心層と、基材層とを別個に形成した後に両者を接合してもよく、中心層の表面に直接基材層を形成してもよい。
中心層に積層された2つの基材層上に、それぞれ電波吸収層を形成する方法としては特に制限はないが、電波吸収層を別個に形成した後に2つの基材層上に電波吸収層を積層してもよく、基材層の表面に直接電波吸収層を形成してもよい。
第4の態様に係る素子は、第1の態様に係る電波吸収積層フィルムを含む。
第4の態様に係る素子としては、携帯電話、無線LAN、ETCシステム、高度道路交通システム、自動車走行支援道路システム、衛星放送等の種々の情報通信システムにおける各種素子(車載素子、高周波アンテナ素子等を含む。)が挙げられる。
車載素子としては、76GHz帯域のミリ波を利用して車間距離等の情報を検知する車載レーダー等の自動車走行支援道路システム用車載素子が挙げられる。
受信アンテナ部に直接入射する電波まで著しく減衰させてしまうことなくアンテナ素子としての機能を果たす観点から、上記高周波アンテナ素子は、高周波アンテナ素子全体としての電波吸収特性を付与する一方で、受信アンテナ部に直接入射する電波を、高周波アンテナ素子が所望する動作を実行できない程度に減衰させないように第1の態様に係る電波吸収積層フィルムを含むことがより好ましい。
上記高周波アンテナ素子の構成として具体的には、第1の態様に係る電波吸収積層フィルムが、受信アンテナ部が載置されていない表面を被覆する構成であって、上記電波吸収積層フィルムが、受信アンテナ部の側面全面に接していてもいなくてもよく、受信アンテナ部の上面の少なくとも一部を被覆していてもしていなくてもよい構成が挙げられる。
上記高周波アンテナ素子としては、受信アンテナ部は、通常、配線により他の部品と接続される。
このため、高周波アンテナ素子において、高周波アンテナ素子の表面の任意の箇所に端子が設けられ、当該端子と、受信アンテナ部とを接続する配線が設けられる構成が挙げられる。
(電波吸収層形成用ペーストの調製)
TMU50.9質量%中、下記イプシロン型酸化鉄35.1質量%、下記カーボンナノチューブ(CNT)2.2質量%、下記分散剤3.5質量%及び下記樹脂8.3質量%を加え、各成分を均一に溶解又は分散させて電波吸収層形成用ペーストを得た。
なお、電波吸収層形成用ペーストの固形分濃度は、49.1質量%であった。
CNTとしては、長径150nmの多層カーボンナノチューブ(商品名VGCF-H;昭和電工社製)を用いた。
分散剤としては、フェニルトリメトキシシランを用いた。
樹脂として、エチルセルロースを用いた。
PETフィルム(厚さ125μm)に上記電波吸収層形成用ペーストを用いてアプリケーターにより塗布した後90℃20分及び130℃20分乾燥を行い厚さ70μmの電波吸収層をPETフィルムに形成し、図2(a)に示した電波吸収層及び基材層の積層体(合計厚さ約200μm)を少なくとも6個得た。
上記積層体のうち1個を比較例1の積層フィルムとして後記の透過減衰量及び反射減衰量試験に供した。
図2(a)は比較例1の積層フィルムの断面図である。
図2(a)中、12は電波吸収層を示し、14は基材層(PETフィルム)を示す。
図2(c)中、32は電波吸収層を示し、34は基材層(PETフィルム)を示す。
上記積層体のうち1個を用いてPETフィルムに厚さ20μmのアルミニウム金属シートをラミネートし、図2(b)に示した比較例2の積層フィルム(合計厚さ約220μm)を形成して後記の透過減衰量及び反射減衰量試験に供した。
図2(b)中、22は電波吸収層を示し、23は中心層(アルミニウム金属層)を示し、24は基材層(PETフィルム)を示す。
図1中、実施例1の電波吸収積層フィルム1は中心層3である金属層と、2つの基材層4であるPETフィルムと、2つの電波吸収層2とを有する。
上記作成した実施例1の電波吸収積層フィルム及び比較例1~3の積層フィルムについて、各々図1及び図2(a)~(c)に示した「上」及び「下」の方向から30~2000GHzの電波を入射させ、その透過減衰量及び反射減衰量をテラヘルツ分光装置(アドバンテスト社製)を用いて、透過及び反射スペクトルを測定した。周波数fにおける透過減衰量Abs(f)は、Abs(f)=-10Log(T(f)/100)で求められる。ここで、T(f)は周波数fにおける透過率(%)である。
周波数fにおける反射減衰量RL(f)は、RL(f)=-10Log(R(f)/100)で求められる。ここで、R(f)は反射率(%)である。
結果を図3~6に示す。
図3(a)に示したように、図1に示した「上」及び「下」のいずれの方向からの入射波に対する透過減衰量も30GHz以上200GHz以下の周波帯域において、絶対値が10dB以上であり良好であることが分かる。これは電波吸収層による吸収効果及び金属層による遮断効果に基づくためと思われる。
図3(b)に示したように、図1に示した「上」及び「下」のいずれの方向からの入射波に対する反射減衰量についても30GHz以上200GHz以下の周波帯域において、絶対値10dB以上のピークが存在することが分かる。これは、上記いずれの方向からの入射波に対しても金属層により反射された反射波が電波吸収層により吸収されることに基づくためと思われる。
図4(a)に示したように、図2(a)に示した「上」及び「下」のいずれの方向からの入射波に対しても透過減衰がほとんど見られないことが分かる。これは1つの電波吸収層のみの吸収に基づくためと思われる。
図4(b)に示したように、図2(a)に示した「上」の方向からの入射波に対する反射減衰が若干見られたものの、「下」の方向からの入射波に対する反射減衰はほとんど見られないことが分かる。これは金属層による反射波がなく電波吸収層表面のみの吸収に基づくためと思われる。
図5(a)に示したように、図2(b)に示した「上」及び「下」のいずれの方向からの入射波に対する透過減衰量も30GHz以上200GHz以下の周波帯域において、絶対値が10dB以上であり良好であることが分かる。これは金属層の存在に基づくためと思われる。
図5(b)に示したように、図2(b)に示した「上」の方向からの入射波に対する反射減衰量については30GHz以上200GHz以下の周波帯域において、絶対値10dB以上のピークが存在することが分かる。これは金属層により反射された反射波が電波吸収層により吸収されたことに基づくと思われる。
一方、図2(b)に示した「下」の方向からの入射波に対しては、金属層が全反射してしまい反射減衰が得られていないことが分かる。
図6(a)に示したように、「上」及び「下」のいずれの方向からの入射波に対しても透過減衰がほとんど見られない比較例1の積層フィルムに比べ、比較例3の積層フィルムは図2(c)に示した「上」及び「下」のいずれの方向からの入射波に対しても電波吸収層が2層になったことから透過減衰量が向上しているものの、金属層による透過波の遮断効果は見られず、透過減衰は不十分であることが分かる。
図6(b)に示したように、図2(c)に示した「上」の方向からの入射波に対する反射減衰量については30GHz以上200GHz以下の周波帯域において、絶対値10dB以上のピークが存在することが分かるものの、「下」の方向からの入射波に対する反射減衰量についてはピークが小さく絶対値10dB以上のピークは見られないことが分かる。これは両方の電波吸収層表面による反射減衰が見られるものの、金属層による反射波ではないことにより安定性に欠けることに基づくと推察される。
(透過減衰量)
○:30GHz以上200GHz以下の周波帯域において、透過減衰量の絶対値が10dB以上
×:30GHz以上200GHz以下の周波帯域において、透過減衰量の絶対値が10dB未満
(反射減衰量)
○:30GHz以上200GHz以下の周波帯域において、反射減衰量の絶対値が10dB以上のピークが存在する。
×:30GHz以上200GHz以下の周波帯域において、反射減衰量の絶対値が10dB以上のピークが存在しない。
一方、比較例1及び3の積層フィルムは透過減衰性及び反射減衰性いずれにも劣ることが分かる。
また、比較例2の積層フィルムは、透過減衰性については良好であるものの、図2(b)に示した「下」の方向からの入射波に対しては、金属層が全反射してしまい反射減衰が得られていないことが分かる。
2 電波吸収層
3 中心層
4 基材層
Claims (9)
- 電波吸収層を有する電波吸収積層フィルムであって、
前記電波吸収積層フィルムが、中心層と、2つの基材層と、2つの電波吸収層とを有し、
前記中心層が、少なくとも1つの金属層を含み、
2つの前記基材層が、前記中心層の両面に積層されており、
2つの前記基材層のそれぞれについて、前記中心層とは反対の面に前記電波吸収層が積層されており、
2つの前記基材層は同一であっても異なっていてもよく、2つの前記電波吸収層は同一であっても異なっていてもよく、
前記電波吸収層の少なくとも1つが磁性体を含む、電波吸収積層フィルム。 - 前記電波吸収積層フィルムの少なくとも一方の面について、30GHz以上300GHz以下の周波帯域において、透過減衰量の絶対値が10dB以上であり、かつ反射減衰量の絶対値が10dB以上のピークを有する、請求項1に記載の電波吸収積層フィルム。
- 厚さ1000μm以下である、請求項1又は2に記載の電波吸収積層フィルム。
- 前記磁性体がイプシロン型酸化鉄、バリウムフェライト磁性体、及びストロンチウムフェライト磁性体よりなる群から選択される少なくとも1つを含む、請求項1~3のいずれか1項に記載の電波吸収積層フィルム。
- 前記磁性体がイプシロン型酸化鉄を含み、
前記イプシロン型酸化鉄がε-Fe2O3結晶、及び、結晶と空間群がε-Fe2O3と同じであって、ε-Fe2O3結晶のFeサイトの一部がFe以外の元素Mで置換されたものであり、式ε-MxFe2-xO3で表され、前記xが0以上2以下である結晶よりなる群から選択される少なくとも1種である、請求項4に記載の電波吸収積層フィルム。 - 請求項1~5のいずれか1項に記載の電波吸収積層フィルムの製造方法であって、
(a1)前記基材層上に前記電波吸収層を形成して電波吸収層及び基材層の積層体を形成することを少なくとも2回行い、前記積層体を少なくとも2つ得ること、及び、
(b1)前記中心層の両面それぞれに、前記積層体の基材層の面を積層させることを含む製造方法。 - 請求項1~5のいずれか1項に記載の電波吸収積層フィルムの製造方法であって、
(a2)前記中心層の両面それぞれに、前記基材層を積層させること、及び
(b2)前記中心層に積層された2つの前記基材層上に、それぞれ電波吸収層を形成することを含む製造方法。 - 前記電波吸収層の形成が、前記磁性体を含むペーストを前記基材層上に塗布することにより行われる、請求項6又は7に記載の製造方法。
- 請求項1~5のいずれか1項に記載の電波吸収積層フィルムを含む素子。
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US11980013B2 (en) | 2024-05-07 |
EP3806597A4 (en) | 2022-03-02 |
EP3806597A1 (en) | 2021-04-14 |
CN112205093A (zh) | 2021-01-08 |
JP7464944B2 (ja) | 2024-04-10 |
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JPWO2019235364A1 (ja) | 2021-08-19 |
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