WO2022173009A1 - 電磁波シールド材及びその製造方法 - Google Patents
電磁波シールド材及びその製造方法 Download PDFInfo
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- WO2022173009A1 WO2022173009A1 PCT/JP2022/005432 JP2022005432W WO2022173009A1 WO 2022173009 A1 WO2022173009 A1 WO 2022173009A1 JP 2022005432 W JP2022005432 W JP 2022005432W WO 2022173009 A1 WO2022173009 A1 WO 2022173009A1
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- Prior art keywords
- fibers
- nonwoven fabric
- layer
- shielding material
- electromagnetic wave
- Prior art date
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Images
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K9/00—Screening of apparatus or components against electric or magnetic fields
- H05K9/0073—Shielding materials
- H05K9/0081—Electromagnetic shielding materials, e.g. EMI, RFI shielding
- H05K9/009—Electromagnetic shielding materials, e.g. EMI, RFI shielding comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K9/00—Screening of apparatus or components against electric or magnetic fields
- H05K9/0073—Shielding materials
- H05K9/0081—Electromagnetic shielding materials, e.g. EMI, RFI shielding
- H05K9/0088—Electromagnetic shielding materials, e.g. EMI, RFI shielding comprising a plurality of shielding layers; combining different shielding material structure
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- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
- B32B5/265—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
- B32B5/266—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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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- 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
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- B32B2262/10—Inorganic fibres
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
- B32B2307/206—Insulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
- B32B2307/212—Electromagnetic interference shielding
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/7375—Linear, e.g. length, distance or width
- B32B2307/7376—Thickness
Definitions
- the present invention relates to an electromagnetic wave shielding material and its manufacturing method.
- Patent Document 1 discloses a molded product obtained by molding a molding material containing carbon fiber, metal fiber, and thermoplastic resin. Moldings made of conductive fiber-containing plastics containing fibers and metal or metal-coated fibers are disclosed.
- An object of the present invention is to provide an electromagnetic shielding material that can effectively shield low-frequency magnetic fields.
- the present inventors have found that a layer A containing inorganic fibers and a layer B containing metal fibers are included, and at least one of the A layer and the B layer contains a resin. It was found that low-frequency magnetic fields can be effectively shielded by using an electromagnetic shielding material containing
- the present invention includes the following inventions.
- An electromagnetic shielding material comprising an A layer containing inorganic fibers and a B layer containing metal fibers, wherein at least one of the A layer and the B layer contains a resin.
- a manufacturing method for manufacturing the electromagnetic shielding material according to [6] above comprising a step of laminating at least one inorganic fiber-containing nonwoven fabric a and at least one metal fiber-containing nonwoven fabric b; and heating and pressurizing the nonwoven fabric, wherein at least one of the nonwoven fabric a and the nonwoven fabric b contains a thermoplastic resin.
- Effectively shielding a low-frequency magnetic field by using an electromagnetic shielding material containing a resin in at least one of the A layer and the B layer, which includes an A layer containing inorganic fibers and a B layer containing metal fibers. can be done.
- FIG. 1 is a cross-sectional photograph of a molded article of Example 1.
- FIG. FIG. 4 is a diagram showing the relationship between frequency and magnetic field shield characteristics in Example 1-1 and Comparative Examples 1-1 and 1-2;
- FIG. 10 is a diagram showing the relationship between frequency and magnetic field shield characteristics in Examples 2-1 to 2-3;
- the electromagnetic shielding material of the present invention includes an A layer containing inorganic fibers and a B layer containing metal fibers. Further, in the electromagnetic wave shielding material of the present invention, at least one of the A layer and the B layer preferably contains a resin, and the A layer preferably contains a resin. In this specification, metal fibers are not included in inorganic fibers.
- the inorganic fibers contained in layer A are not particularly limited, but preferably contain at least one of carbon fiber, glass fiber, and natural mineral fiber, more preferably contain at least one of carbon fiber and glass fiber, and contain carbon fiber. More preferably, it contains fibers.
- the carbon fiber is not particularly limited, and includes PAN-based carbon fiber, pitch-based carbon fiber, rayon-based carbon fiber, cellulose-based carbon fiber, vapor growth-based carbon fiber, and graphitized fibers thereof. Two or more types can be used.
- the carbon fibers preferably contain PAN-based carbon fibers.
- PAN-based carbon fibers are carbon fibers made from polyacrylonitrile fibers.
- Pitch-based carbon fibers are carbon fibers made from petroleum tar or petroleum pitch.
- Cellulose-based carbon fibers are carbon fibers made from viscose rayon, cellulose acetate, or the like.
- Vapor-grown carbon fibers are carbon fibers made from hydrocarbons or the like.
- the average fiber length of the inorganic fibers is preferably 15-100 mm, more preferably 30-90 mm, and even more preferably 40-80 mm.
- the average fiber length is 15 mm or more, the mechanical strength of the layer A is easily maintained, and the mechanical strength of the electromagnetic wave shielding material is easily maintained.
- the average fiber length is 100 mm or less, the dispersibility of the inorganic fibers in the A layer can be enhanced.
- Layer A may contain only inorganic fibers or may contain inorganic fibers and resins. However, since inorganic fibers have weaker dispersibility and less entanglement between fibers than other fibers such as metal fibers, inorganic fibers and resins should be included. is preferred.
- the resin contained in layer A is not particularly limited, and may be a thermoplastic resin or a thermosetting resin, but is preferably a thermoplastic resin.
- the thermoplastic resin is not particularly limited as long as it is a synthetic resin that has elasticity at room temperature, is difficult to deform, and can be softened by heating and molded into a desired shape. Examples include polyolefin resin, polyester resin, Examples include polyamide resins, polyurethane resins, (meth)acrylic resins, polycarbonate resins, polystyrene resins, polyphenylene sulfide resins, and the like.
- thermosetting resins include phenol resins, epoxy resins, urea resins, melamine resins, and diallyl phthalate resins.
- thermoplastic resin may be an acid-modified thermoplastic resin.
- An acid-modified thermoplastic resin is a thermoplastic resin into which an acid-modified group has been introduced by acid modification.
- the type of acid-modifying group is not particularly limited, and only one type of acid-modifying group may be included, or two or more types may be included. —COOH).
- the acid-modifying group may be introduced by any compound.
- carboxylic anhydrides include maleic anhydride, itaconic anhydride, succinic anhydride, glutaric anhydride, and adipic anhydride.
- the acid include maleic acid, itaconic acid, fumaric acid, acrylic acid, and methacrylic acid. Among them, carboxylic acid is preferable, and maleic acid is more preferable.
- the term "thermoplastic resin” includes both acid-modified thermoplastic resins and non-acid-modified thermoplastic resins.
- the content of inorganic fibers in layer A is preferably 10% by mass or more, more preferably 20% by mass or more, further preferably 30% by mass or more, and 70% by mass or less. It is preferably 60% by mass or less, more preferably 50% by mass or less.
- the content of the resin in the layer A is preferably 20% by mass or more, more preferably 35% by mass or more, even more preferably 50% by mass or more, and preferably 80% by mass or less. , 70% by mass or less.
- the total content of the inorganic fibers and the resin in the A layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 90% by mass or more, and 95% by mass. is particularly preferred, and 100% by mass is most preferred.
- the A layer may contain metal fibers as long as the effects of the present invention are not impaired, it is preferable that the layer contains little or no metal fibers.
- the content of metal fibers in layer A is preferably less than 10% by mass, more preferably 5% by mass or less, and even more preferably 1% by mass or less.
- the B layer contains metal fibers.
- the metal component constituting the metal fiber is not particularly limited, and may be a base metal such as copper, iron, aluminum, nickel, chromium, or an alloy such as stainless steel, gold, platinum, silver, palladium. , rhodium, iridium, ruthenium, and osmium.
- the metal component constituting the metal fiber is preferably at least one of base metals and alloys from the viewpoint of productivity and material cost, more preferably a base metal, has a high conductivity, and has a relatively thin layer.
- copper is more preferable.
- the fiber diameter of the metal fibers is preferably 10-100 ⁇ m, more preferably 20-70 ⁇ m.
- the fiber diameter is 10 ⁇ m or more, the mechanical strength of the layer B is easily maintained, and the mechanical strength of the electromagnetic wave shielding material is easily maintained.
- the fiber diameter is 100 ⁇ m or less, the dispersibility of the metal fibers in the B layer can be enhanced.
- the content of metal fibers in layer B is preferably 50% by mass or more, more preferably 70% by mass or more, further preferably 90% by mass or more, and 95% by mass or more. Especially preferred.
- the B layer may or may not contain resin.
- the resin content in layer B is preferably 50% by mass or less, more preferably 30% by mass or less, and even more preferably 10% by mass or less.
- the total content of the metal fibers and the resin in the B layer is preferably 50% by mass or more, more preferably 70% by mass or more, even more preferably 90% by mass or more, and 95% by mass. is particularly preferred, and 100% by mass is most preferred.
- the B layer may contain inorganic fibers as long as the effects of the present invention are not impaired.
- the content of inorganic fibers in layer B is preferably less than 10% by mass, more preferably 5% by mass or less, and even more preferably 1% by mass or less.
- the content of metal fibers is preferably 90% or more, more preferably 100%.
- An image of 200 ⁇ m square is taken using an optical microscope on a plane perpendicular to the thickness direction at approximately the center in the thickness direction of the layer B, and the number of metal fibers and inorganic fibers contained in the image is confirmed.
- the ratio of the number of metal fibers to the total number of fibers is defined as the content of metal fibers.
- the region includes a certain region, and a region in which the metal fibers are not dispersed partially may exist to the extent that the effect of the present invention is not impaired.
- the short side is P ( ⁇ m)
- an image of P ( ⁇ m) ⁇ 200 ( ⁇ m) is taken and the metal fiber and the inorganic fiber Calculate the ratio of the number of metal fibers to the total number of, and if both the vertical and horizontal sides are less than 200 ⁇ m, check the number of all metal fibers and inorganic fibers present in the plane perpendicular to the thickness direction of the B layer, Calculate the ratio of the number of metal fibers to the total number of metal fibers and inorganic fibers.
- the average fiber length of the metal fibers is preferably 25-200 mm, more preferably 50-150 mm, even more preferably 80-120 mm.
- the average fiber length is 25 mm or more, the mechanical strength of the layer B is easily maintained, and the mechanical strength of the electromagnetic wave shielding material is easily maintained.
- the average fiber length is 200 mm or less, the dispersibility of the metal fibers in the B layer can be enhanced.
- the basis weight of the electromagnetic wave shielding material of the present invention is preferably 500 to 5,000 g/m 2 , more preferably 1,000 to 4,000 g/m 2 from the viewpoint of smooth processing of molded products for automobile parts and the like. It is more preferably 1500 to 3500 g/m 2 , still more preferably 2000 to 3000 g/m 2 and particularly preferably 2000 to 2500 g/m 2 .
- the thickness of the electromagnetic wave shielding material of the present invention is preferably 0.5 to 6.0 mm, more preferably 1.0 to 5.0 mm, from the viewpoint of smooth processing of molded products such as automobile parts. It is preferably 1.5 to 4.0 mm, particularly preferably 1.5 to 3.0 mm, and most preferably 1.5 to 2.5 mm.
- the magnetic field shielding performance SE is preferably 3 dB or more at 0.1 MHz, more preferably 8 dB or more, preferably 10 dB or more at 1 MHz, and 20 dB or more. is more preferably 20 dB or more at 10 MHz, more preferably 35 dB or more, preferably 40 dB or more at 100 MHz, more preferably 50 dB or more, and 60 dB or more at 500 MHz. Preferably, it is 75 dB or more.
- the magnetic field shielding performance SE is based on the KEC method, where the magnetic field strength in a space without an electromagnetic shielding material is M (A / m), and the magnetic field strength when the electromagnetic shielding material is arranged is M' (A / m). is a value obtained based on the following formula.
- the KEC method is a method for measuring the electromagnetic shielding effect using an electromagnetic shielding effect measuring device developed by the Kansai Electronics Industry Promotion Center, and is a known method.
- Magnetic field shield performance SE (dB) 20 log 10 (M/M')
- the A layer contains a relatively large amount of inorganic fibers
- the B layer contains a relatively large amount of metal fibers.
- "contains a relatively large amount of inorganic fibers” means that a large amount of inorganic fibers is contained compared to the content of inorganic fibers in the entire electromagnetic shielding material, and "contains a relatively large amount of metal fibers” does not mean that It means that the metal fiber is contained more than the content rate of the metal fiber in the whole electromagnetic wave shielding material.
- the A layer and the B layer are adjacent, but the boundary line between the A layer and the B layer may not be clear, and both the inorganic fiber and the metal fiber are included between the A layer and the B layer.
- An intermediate layer may be present.
- the layer structure of the electromagnetic wave shielding material is not particularly limited, and the surface of the electromagnetic wave shielding material may be an A layer or a B layer.
- the electromagnetic wave shielding material has at least one layer each of the A layer and the B layer.
- An electromagnetic wave shielding material laminated in the order of A layer/B layer/A layer is more preferable because it reduces warpage when molded.
- FIG. 1 is a cross-sectional photograph of an electromagnetic wave shielding material (molded body) of Example 1, which will be described later.
- the layer located closer to the letters "1000.00 ⁇ m" in FIG. 1 is the A layer, and the layer located farther from the letters "1000.00 ⁇ m" in FIG.
- the thin layer is the B layer.
- the electromagnetic wave shielding material of Example 1 has an A layer containing a relatively large amount of inorganic fibers and a B layer containing a relatively large amount of metal fibers.
- the B layer is located on the surface of the molded body, but the entire surface of the molded body does not necessarily have to be covered with metal fibers (the metal fiber content is 90% or more. area), and there may be a partial area where the metal fibers are not dispersed to the extent that the effect of the present invention is not impaired (see FIG. 1).
- the electromagnetic wave shielding material of the present invention has a structure in which a relatively large amount of inorganic fibers are dispersed in the A layer, and a relatively large amount of metal fibers are dispersed in the B layer. It also has excellent mechanical properties such as flexural modulus and flexural modulus, and can be used for molding involving elongation.
- a manufacturing method for manufacturing an electromagnetic wave shielding material containing a thermoplastic resin comprises a step of laminating at least one inorganic fiber-containing nonwoven fabric a and at least one metal fiber-containing nonwoven fabric b, and heating and heating the laminated nonwoven fabric. and pressing, and at least one of the nonwoven fabric a and the nonwoven fabric b contains a thermoplastic resin.
- heating and pressurization are performed in all examples, but heating and pressurization are not essential, and depending on the embodiment, for example, a laminate obtained by laminating the nonwoven fabric a and the nonwoven fabric b ( A laminate without heating and pressurization) may be used as an electromagnetic shielding material, or a laminate obtained by laminating the nonwoven fabric a and the nonwoven fabric b only by heating may be used as an electromagnetic shielding material. good too.
- a manufacturing method for manufacturing an electromagnetic shielding material containing a thermoplastic resin includes a step of laminating at least one inorganic fiber-containing nonwoven fabric a and at least one metal fiber-containing nonwoven fabric b, and heat-press molding the laminated nonwoven fabric. It is more preferable that the nonwoven fabric a contains a resin.
- a manufacturing method for manufacturing an electromagnetic shielding material containing a thermosetting resin includes a step of laminating at least one inorganic fiber-containing nonwoven fabric a and at least one metal fiber-containing nonwoven fabric b, and thermosetting the laminated nonwoven fabric. It is preferable that the production method includes a step of adding a thermosetting resin composition and a step of curing the thermosetting resin composition by heating. In addition, you may pressurize at the time of the said heating.
- the method for heating and pressurizing the laminated nonwoven fabric is not particularly limited, and known methods can be used. For example, from the viewpoint of operability and versatility, it is preferable to perform press molding using a hot press machine.
- the applied pressure is preferably 0.1 to 15 MPa, more preferably 0.5 to 10 MPa, still more preferably 1 to 7 MPa, taking into account the strength of the molded article to be obtained.
- the heating time is preferably 30 to 300 seconds, more preferably 40 to 240 seconds, still more preferably 50 to 180 seconds.
- the heating temperature is preferably from the melting point of the resin to the melting point +100°C in consideration of the melting point of the resin contained in the nonwoven fabric a, and more preferably from the melting point of the resin +20°C to the melting point +100°C. , More preferably, the melting point of the resin +40 ° C. to +100 ° C.
- the heating temperature is preferably 160 to 270 ° C., more preferably 180 to 260 ° C., and 200 More preferably ⁇ 250°C.
- the heating temperature may be determined according to the type of thermosetting resin to be used, and the thermosetting resin is produced under known conditions. do it.
- thermoplastic resin film containing inorganic fibers instead of the nonwoven fabric containing inorganic fibers a, and a thermoplastic resin film containing metal fibers instead of the nonwoven fabric containing metal fibers b. It is also possible to manufacture an electromagnetic wave shielding material using it.
- a method for producing a thermoplastic resin film containing inorganic fibers for example, inorganic fibers are dispersed on a thermoplastic resin film, the thermoplastic resin is melted by heat, and pressure is applied as necessary to form a thermoplastic resin film. and inorganic fibers.
- a thermoplastic resin film containing metal fibers can also be produced in the same manner as a thermoplastic resin film containing inorganic fibers.
- Both the nonwoven fabric a and the nonwoven fabric b may be one, or two or more, but it is preferable that the nonwoven fabric a is two or more and the nonwoven fabric b is only one.
- the nonwoven fabric a preferably contains a thermoplastic resin in addition to inorganic fibers.
- the thermoplastic resin it is preferable to use thermoplastic resin fibers or thermoplastic resin particles, and thermoplastic resin fibers are used (that is, the nonwoven fabric a is a nonwoven fabric in which inorganic fibers and thermoplastic resin fibers are mixed). is more preferred.
- the thermoplastic resin fiber is preferably a fiber containing at least one selected from polypropylene resin, polyamide resin, and polycarbonate resin.
- the average fiber length of the thermoplastic resin fibers is preferably 25-100 mm, more preferably 30-80 mm, even more preferably 40-70 mm.
- the average fiber length is 25 mm or more, the mechanical strength is improved when a molded article made of a nonwoven fabric containing inorganic fibers and thermoplastic resin fibers is molded.
- the average fiber length is 100 mm or less, the dispersibility of the resin fibers and the thermoplastic resin fibers in the nonwoven fabric is improved, making it easier to form a uniform nonwoven fabric.
- the fineness of the thermoplastic resin fibers is preferably 2 to 22 dtex, more preferably 3 to 15 dtex, even more preferably 4 to 10 dtex.
- the fineness is 2 dtex or more or 22 dtex or less, the dispersibility of the inorganic fibers and the thermoplastic resin fibers in the nonwoven fabric is improved, making it easier to form a uniform nonwoven fabric.
- the basis weight of the nonwoven fabric a is preferably 400 to 4000 g/m 2 , more preferably 800 to 3200 g/m 2 , still more preferably 1200 to 2800 g/m 2 , and even more preferably 1600 to 2400 g/m 2 . is even more preferable.
- the nonwoven fabric a In the manufacture of the electromagnetic wave shielding material, only one sheet of the nonwoven fabric a may be used, or two or more sheets may be used. When two or more nonwoven fabrics a are used, the same nonwoven fabric a may be used, or different nonwoven fabric a may be used, but the same nonwoven fabric a is preferably used. When different nonwoven fabrics a are used, the terms "inorganic fiber content in nonwoven fabric a" and “resin content in nonwoven fabric a” refer to the inorganic fiber content and resin content in all nonwoven fabrics a. In addition, in the case of an electromagnetic shielding material in which two or more nonwoven fabrics a are laminated, the "nonwoven fabric a" refers to the sum of the fabric weights of all the nonwoven fabrics a.
- the method for producing the nonwoven fabric a is not particularly limited.
- the nonwoven fabric a is produced by mixing inorganic fibers and thermoplastic resin fibers to form a sheet, and finally bonding the inorganic fibers and the thermoplastic resin fibers.
- the production method (1) above is preferred.
- an inorganic fiber bundle is opened, and the opened inorganic fiber and the thermoplastic resin fiber are mixed at a desired mass ratio (for example, 40% by mass of inorganic fiber, thermoplastic 60% by mass of resin fibers) to form a sheet, and finally, the inorganic fibers and the thermoplastic resin fibers are bonded by heating or pressing to obtain the nonwoven fabric a.
- a commercially available blender can be used for blending.
- a carding method can be used.
- carding can be performed using a commercially available carding machine such as a carding nonwoven fabric manufacturing apparatus.
- Inorganic fibers and thermoplastic resin fibers can be bonded by known bonding methods such as thermal bonding and resin bonding. Among them, thermal bonding is preferably performed using a belt press or the like.
- the resin particles can be attached by spraying the thermoplastic resin particles onto the inorganic fibers, and the inorganic fibers to which the thermoplastic resin particles are attached are heated or pressurized to combine with the inorganic fibers.
- the nonwoven fabric a can be produced by bonding with a thermoplastic resin.
- thermoplastic resin or a thermosetting resin
- the impregnation method include impregnation using a press machine, a double belt press machine, or the like, or a transfer molding method.
- the dipping method includes a pultrusion method, a prepreg method, a winding method, and the like.
- Examples of the production method of (4) above include a method of entangling inorganic fibers by needle punching or the like, a method of making paper from short inorganic fibers, a method of weaving inorganic fibers using a loom or the like, and a method of weaving inorganic fibers. Examples include a method of applying pressure after fiberizing into a sheet.
- the method for producing the nonwoven fabric b is not particularly limited, and examples thereof include a method of entangling inorganic fibers by needle punching or the like, a method of making paper from short inorganic fibers, and a method of weaving inorganic fibers using a loom.
- the nonwoven fabric b is preferably a nonwoven fabric made only of metal fibers, but may contain a resin.
- the resin contained in the nonwoven fabric b is not particularly limited, and may be a thermoplastic resin or a thermosetting resin. Specific examples of the thermoplastic resin and thermosetting resin contained in the nonwoven fabric b are the same as the resin contained in the nonwoven fabric a, and the method for producing the nonwoven fabric b containing the resin is described in (1) to ( Any manufacturing method of 3) may be used.
- the nonwoven fabric b preferably has a basis weight of 100 to 1,000 g/m 2 , more preferably 150 to 700 g/m 2 , even more preferably 200 to 400 g/m 2 .
- the nonwoven fabric b In the manufacture of the electromagnetic wave shielding material, only one sheet of the nonwoven fabric b may be used, or two or more sheets may be used. When using two or more nonwoven fabrics b, the same nonwoven fabric b may be used, or different nonwoven fabrics b may be used. When different nonwoven fabrics b are used, in the electromagnetic wave shielding material in which two or more nonwoven fabrics b are laminated, the "weight per unit area of nonwoven fabric b" refers to the total weight per unit area of all nonwoven fabrics b.
- Magnetic field shield performance SE (dB) 20 log 10 (M/M')
- carbon fiber T700, 70 mm cut fiber manufactured by Toray Industries, Inc.
- maleic acid-modified polypropylene fiber manufactured by Daiwabo Co., Ltd., fineness 4.4 dT, average Fiber length 51 mm
- copper fiber manufactured by Nikko Techno Co., Ltd., fiber diameter 50 ⁇ m, average fiber length 100 mm
- nickel fiber manufactured by Nikko Techno Co., Ltd., fiber diameter 40 ⁇ m, average fiber length 100 mm
- iron fibers manufactured by Nikko Techno Co., Ltd., fiber diameter 50 ⁇ m, average fiber length 100 mm.
- Example 1-1 (molded body 1)> 40% by mass of the carbon fiber and 60% by mass of the maleic acid-modified polypropylene fiber are blended to produce a web using a carding nonwoven fabric production device, and then a low-pressure belt press using heat to a thickness of 0.8 mm.
- 8 sheets of nonwoven fabric a1 are laminated on one side of copper fiber nonwoven fabric b1 (basis weight: 300 g/m 2 ) manufactured by Nikko Techno Co., Ltd. manufactured by needle punching the above copper fibers, and nonwoven fabric laminate 1 (basis weight: 2300 g/m 2 and an apparent thickness of 10 mm).
- the nonwoven fabric laminate 1 was press-molded using a hot press under the conditions of a temperature of 230° C., a pressure of 5 MPa, and a pressing time of 60 seconds. Finally, it was cooled to obtain a compact 1 having a thickness of 2 mm.
- the state of the cross section of the molded product 1 obtained in Example 1 was observed with an optical microscope (VHX-900 manufactured by KEYENCE) to examine the arrangement of copper fibers. It was confirmed that the content of copper fibers was 90% or more among the fibers contained in the 200 ⁇ m square on the surface of the molded body 1 . That is, in the molded body 1, a layer A containing a relatively large amount of carbon fibers and a layer B containing a relatively large amount of copper fibers (a layer containing a large amount of copper fibers compared to the content of copper fibers in the entire molded body 1 ) is formed, and the B layer in which the copper fibers are substantially uniformly dispersed is present on the A layer.
- VHX-900 manufactured by KEYENCE
- ⁇ Comparative Example 1-1 (molded body 2)> 40% by mass of the carbon fiber, 15% by mass of the copper fiber, and 45% by mass of the maleic acid-modified polypropylene fiber are blended to produce a web using a carding nonwoven fabric production apparatus, and then a low-pressure belt press machine using heat.
- Nine nonwoven fabrics c having a basis weight of 250 g/m 2 were produced.
- nine nonwoven fabrics c were laminated to produce a nonwoven fabric laminate 2 (basis weight: 2250 g/m 2 , apparent thickness: 8 mm).
- the nonwoven fabric laminate 2 was press-molded using a hot press under conditions of a temperature of 230° C., a pressure of 5 MPa, and a pressing time of 60 seconds.
- the press-molded nonwoven fabric laminate 2 was cooled to obtain a molded body 2 having a thickness of 2 mm.
- a nonwoven fabric laminate 3 (basis weight: 2250 g/m 2 , apparent thickness: 8 mm) was prepared by laminating nine layers of the above nonwoven fabric a1. After that, the nonwoven fabric laminate 3 was press-molded using a hot press under conditions of a temperature of 230° C., a pressure of 5 MPa, and a pressing time of 60 seconds. Finally, the press-molded nonwoven fabric laminate 3 was cooled to obtain a molded body 3 having a thickness of 2 mm.
- the magnetic field shielding performance SE at frequencies of 0.1 to 1000 MHz was obtained for compacts 1 to 3 (Example 1-1, Comparative Examples 1-1 and 1-2), and a diagram showing the relationship between the frequency and the magnetic shielding performance SE is shown in FIG. It was shown to.
- Table 1 shows magnetic field shield performance SE (unit: dB) of compacts 1 to 3 at frequencies of 0.1 MHz, 1 MHz, 10 MHz, 100 MHz and 500 MHz.
- the compact 1 which is an example, has a very excellent magnetic field shielding performance SE at any frequency from 0.1 to 500 MHz. Therefore, since the molded body 1 is a molded body in which the layer A containing carbon fibers and the layer B containing copper fibers are separately present, the low-frequency magnetic field can be effectively shielded.
- the molded article of Example 1 had an electric field shielding property comparable to that of the molded article of Comparative Example 1, and the molded article of Example 1 was excellent not only in the magnetic field shielding property but also in the electric field shielding property. .
- Example 2-1 (molded body 4)> A nonwoven fabric laminate 4 (basis weight: 2300 g/m 2 , apparent thickness: 10 mm) was prepared by laminating four layers of the nonwoven fabric a1 on each side of the nonwoven fabric b1. After that, the nonwoven fabric laminate 4 was press-molded using a hot press under conditions of a temperature of 230° C., a pressure of 5 MPa, and a pressing time of 60 seconds. Finally, cooling was performed to obtain a compact 4 having a thickness of 2 mm.
- Example 2-2 (molded body 5)> A molded article was produced in the same manner as in Example 2-1, except that instead of the nonwoven fabric b1, the nickel fiber nonwoven fabric b2 (basis weight: 300 g/m 2 ) manufactured by Nikko Techno Co., Ltd., which was produced by needle-punching the nickel fiber, was used. A compact 5 having a basis weight of 2300 g/m 2 and a thickness of 2 mm was obtained.
- Example 2-3 (molded body 6)> A molded body was produced in the same manner as in Example 2-1, except that instead of the nonwoven fabric b1, the Nikko Techno Iron Fiber nonwoven fabric b3 (basis weight: 300 g/m 2 ) produced by needle-punching the iron fibers was used. A compact 6 having a basis weight of 2300 g/m 2 and a thickness of 2 mm was obtained.
- the magnetic field shielding performance SE was determined for molded bodies 4 to 6 (Examples 2-1 to 2-3) at frequencies of 0.1 to 1000 MHz, and a diagram showing the relationship between the frequency and the magnetic field shielding performance SE is shown in FIG. Table 2 shows the magnetic field shield performance SE (unit: dB) of molded bodies 4 to 6 at frequencies of 0.1 MHz, 1 MHz, 10 MHz, 100 MHz and 500 MHz.
- Molded bodies 4 to 6 of Examples have excellent magnetic field shielding performance SE at any frequency of 0.1 to 500 MHz. Are better. Therefore, since the molded bodies 4 to 6 are molded bodies in which the A layer containing the carbon fiber and the B layer containing the metal fiber are separately present, the low-frequency magnetic field can be effectively shielded. Among them, the use of copper fiber as the metal fiber can greatly improve the shielding property.
- the molded articles of Examples 2-1 to 2-3 have the same level of electric field shielding properties as the molded article of Example 1-1, and Examples 2-1 to 3 have not only magnetic field shielding properties but also electric field shielding properties. It was a molded product with excellent properties.
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Abstract
Description
[1]無機繊維を含むA層と金属繊維を含むB層とを含み、前記A層及び前記B層の少なくとも一方に樹脂を含むことを特徴とする電磁波シールド材。
[2]前記無機繊維は、炭素繊維、ガラス繊維、及び天然鉱物繊維の少なくとも一種を含む上記[1]に記載の電磁波シールド材。
[3]厚みが0.5~6.0mmである上記[1]又は[2]に記載の電磁波シールド材。
[4]目付が500~5000g/m2である上記[1]~[3]のいずれかに記載の電磁波シールド材。
[5]前記B層に含まれる繊維のうち、金属繊維の含有率は90%以上である上記[1]~[4]のいずれかに記載の電磁波シールド材。
[6]前記樹脂は熱可塑性樹脂である上記[1]~[5]のいずれかに記載の電磁波シールド材。
[7]上記[1]~[6]のいずれかに記載の電磁波シールド材である成形体。
[8]上記[6]に記載の電磁波シールド材を製造する製造方法であって、少なくとも1枚の無機繊維含有不織布aと少なくとも1枚の金属繊維含有不織布bとを積層する工程と、前記積層した不織布を加熱及び加圧する工程とを有し、前記不織布a及び前記不織布bの少なくとも一方に熱可塑性樹脂が含まれていることを特徴とする製造方法。
A層に含まれる無機繊維としては、特に限定されないが、炭素繊維、ガラス繊維、及び天然鉱物繊維の少なくとも一種を含むことが好ましく、炭素繊維及びガラス繊維の少なくとも一種を含むことがより好ましく、炭素繊維を含むことがさらに好ましい。
B層は金属繊維を含む。金属繊維を構成する金属成分としては、特に限定されず、銅、鉄、アルミニウム、ニッケル、クロム等の卑金属であってもよく、ステンレス等の合金であってもよく、金、白金、銀、パラジウム、ロジウム、イリジウム、ルテニウム、及びオスミウム等の貴金属であってもよい。これらの中でも金属繊維を構成する金属成分としては、生産性、材料コストの観点から卑金属及び合金の少なくとも一種であることが好ましく、卑金属であることがより好ましく、導電率が高く、比較的薄い層でも高いシールド性が期待できるという観点から、銅であることがさらに好ましい。
本発明の電磁波シールド材の目付は、自動車部品用途等の成型品加工をスムーズに行なうという観点から500~5000g/m2であることが好ましく、1000~4000g/m2であることがより好ましく、1500~3500g/m2であることがさらに好ましく、2000~3000g/m2であることがさらに好ましく、2000~2500g/m2であることが特に好ましい。
磁界シールド性能SE(dB)=20・log10(M/M’)
熱可塑性樹脂を含む電磁波シールド材を製造する製造方法としては、少なくとも1枚の無機繊維含有不織布aと少なくとも1枚の金属繊維含有不織布bとを積層する工程と、前記積層した不織布を加熱及び加圧する工程とを有し、前記不織布a及び前記不織布bの少なくとも一方に熱可塑性樹脂が含まれていることを特徴とする製造方法であることが好ましい。後述の実施例では全ての実施例で加熱及び加圧を行っているが、加熱や加圧は必須ではなく、実施形態次第では、例えば、前記不織布aと前記不織布bとを積層した積層体(加熱及び加圧を行っていない積層体)を電磁波シールド材として用いてもよいし、前記不織布aと前記不織布bとを積層した積層体に対して加熱のみ行ったものを電磁波シールド材として用いてもよい。熱可塑性樹脂を含む電磁波シールド材を製造する製造方法としては、少なくとも1枚の無機繊維含有不織布aと少なくとも1枚の金属繊維含有不織布bとを積層する工程と、前記積層した不織布を熱プレス成形する工程とを有し、前記不織布aには樹脂が含まれていることがより好ましい。
前記不織布aは、無機繊維の他に熱可塑性樹脂を含むことが好ましい。前記熱可塑性樹脂としては、熱可塑性樹脂繊維又は熱可塑性樹脂粒子を用いることが好ましく、熱可塑性樹脂繊維を用いる(すなわち、不織布aは無機繊維と熱可塑性樹脂繊維とを混綿した不織布である)ことがより好ましい。熱可塑性樹脂繊維としては、生産性、材料コスト等の観点から、ポリプロピレン樹脂、ポリアミド樹脂、及びポリカーボネート樹脂から選択される少なくとも一種を含む繊維であることが好ましい。
不織布bの製造方法は特に限定されず、例えば、無機繊維をニードルパンチ等により絡ませる方法、短繊維化した無機繊維を抄造する方法、織機などを用いて無機繊維を織る方法等が挙げられる。
縦150mm、横150mmの成形体の質量を市販の電子秤で測定し、測定した質量を面積(0.225m2)で割ることで成形体の目付(単位:g/m2)を算出した。
実施例及び比較例において、市販の厚みゲージによりプレス成形前の不織布積層体及びプレス成形後の成形体の見かけ厚みをそれぞれ測定した。
縦150mm、横150mmの成形体1~6を用意し、関西電子工業振興センターで開発された電磁波シールド効果測定装置を用いて各成形体の周波数0.1~1000MHzにおける電磁波シールド材がない空間の磁界強度M(A/m)及び電磁波シールド材を配置したときの磁界強度M’(A/m)を測定し、下記の式に基づき各周波数における磁界シールド性能SEを算出した。
磁界シールド性能SE(dB)=20・log10(M/M’)
上記炭素繊維40質量%と上記マレイン酸変性ポリプロピレン繊維60質量%とを混綿し、カーディング不織布作製装置を用いてウェブを作製した後、熱を用いた低圧ベルトプレス機にて厚み0.8mm、目付250g/m2の不織布a1を作製した。次に上記銅繊維をニードルパンチして作製された株式会社日工テクノ製銅繊維不織布b1(目付300g/m2)の一方の面に不織布a1を8枚積層させて、不織布積層体1(目付2300g/m2、見かけ厚み10mm)を作製した。その後、熱プレス機を用いて不織布積層体1を、温度230℃、圧力5MPa、加圧時間60秒の条件下でプレス成形を行った。最後に冷却をし、厚み2mmの成形体1を得た。
上記炭素繊維40質量%、上記銅繊維15質量%、及び上記マレイン酸変性ポリプロピレン繊維45質量%を混綿し、カーディング不織布作製装置を用いてウェブを作製した後、熱を用いた低圧ベルトプレス機にて目付250g/m2の不織布cを9つ作製した。次に9つの不織布cを積層させて、不織布積層体2(目付2250g/m2、見かけ厚み8mm)を作製した。その後、熱プレス機を用いて不織布積層体2を、温度230℃、圧力5MPa、加圧時間60秒の条件下でプレス成形を行った。最後にプレス成形された不織布積層体2の冷却を行い、厚み2mmの成形体2を得た。
上記不織布a1を9層積層させた不織布積層体3(目付2250g/m2、見かけ厚み8mm)を作製した。その後、熱プレス機を用いて不織布積層体3を、温度230℃、圧力5MPa、加圧時間60秒の条件下でプレス成形を行った。最後にプレス成形された不織布積層体3の冷却を行い、厚み2mmの成形体3を得た。
上記不織布b1の両面に上記不織布a1をそれぞれ4層ずつ積層させた不織布積層体4(目付2300g/m2、見かけ厚み10mm)を作製した。その後、熱プレス機を用いて不織布積層体4を、温度230℃、圧力5MPa、加圧時間60秒の条件下でプレス成形を行った。最後に冷却を行い、厚み2mmの成形体4を得た。
上記不織布b1に代えて上記ニッケル繊維をニードルパンチして作製された株式会社日工テクノ製ニッケル繊維不織布b2(目付300g/m2)を用いた以外は実施例2-1と同様に成形体を作製し、目付2300g/m2、厚み2mmの成形体5を得た。
上記不織布b1に代えて上記鉄繊維をニードルパンチして作製された株式会社日工テクノ製鉄繊維不織布b3(目付300g/m2)を用いた以外は実施例2-1と同様に成形体を作製し、目付2300g/m2、厚み2mmの成形体6を得た。
Claims (8)
- 無機繊維を含むA層と金属繊維を含むB層とを含み、前記A層及び前記B層の少なくとも一方に樹脂を含むことを特徴とする電磁波シールド材。
- 前記無機繊維は、炭素繊維、ガラス繊維、及び天然鉱物繊維の少なくとも一種を含む請求項1に記載の電磁波シールド材。
- 厚みが0.5~6.0mmである請求項1又は2に記載の電磁波シールド材。
- 目付が500~5000g/m2である請求項1~3のいずれか1項に記載の電磁波シールド材。
- 前記B層に含まれる繊維のうち、金属繊維の含有率は90%以上である請求項1~4のいずれか1項に記載の電磁波シールド材。
- 前記樹脂は熱可塑性樹脂である請求項1~5のいずれか1項に記載の電磁波シールド材。
- 請求項1~6のいずれか1項に記載の電磁波シールド材である成形体。
- 請求項6に記載の電磁波シールド材を製造する製造方法であって、少なくとも1枚の無機繊維含有不織布aと少なくとも1枚の金属繊維含有不織布bとを積層する工程と、前記積層した不織布を加熱及び加圧する工程とを有し、前記不織布a及び前記不織布bの少なくとも一方に熱可塑性樹脂が含まれていることを特徴とする製造方法。
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JPH0653688A (ja) | 1992-07-31 | 1994-02-25 | Kobe Steel Ltd | 電磁波シールド用成形品 |
JP2001267787A (ja) * | 2000-03-15 | 2001-09-28 | Aica Kogyo Co Ltd | 成形板 |
JP2011144473A (ja) * | 2010-01-14 | 2011-07-28 | Mitsubishi Plastics Inc | 炭素繊維/熱可塑性樹脂複合材及びその製造方法、並びに電界シールド材 |
JP2012229345A (ja) | 2011-04-27 | 2012-11-22 | Toray Ind Inc | 成形品 |
JP2016219466A (ja) * | 2015-05-14 | 2016-12-22 | トヨタ紡織株式会社 | 電磁波シールド材 |
JP2020526029A (ja) * | 2017-09-30 | 2020-08-27 | シーアールアールシー チンタオ シーファン カンパニー,リミティッド | ニッケルめっき炭素繊維膜、その製造方法、シールド構造及びその作製方法 |
JP2021021249A (ja) | 2019-07-29 | 2021-02-18 | 壮太 木村 | ドアガードクッション |
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US5312678A (en) * | 1989-10-06 | 1994-05-17 | The Dow Chemical Company | Camouflage material |
JPH0745989A (ja) * | 1993-07-28 | 1995-02-14 | Kobe Steel Ltd | 電磁波シールド材 |
JP2007335680A (ja) * | 2006-06-15 | 2007-12-27 | Sekisui Plastics Co Ltd | 電波吸収体 |
JP6596293B2 (ja) * | 2015-10-08 | 2019-10-23 | 三菱ケミカルアドバンスドマテリアルズコンポジット株式会社 | 積層板、型成形品、積層板の製造方法及び型成形品の製造方法 |
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Patent Citations (7)
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JPH0653688A (ja) | 1992-07-31 | 1994-02-25 | Kobe Steel Ltd | 電磁波シールド用成形品 |
JP2001267787A (ja) * | 2000-03-15 | 2001-09-28 | Aica Kogyo Co Ltd | 成形板 |
JP2011144473A (ja) * | 2010-01-14 | 2011-07-28 | Mitsubishi Plastics Inc | 炭素繊維/熱可塑性樹脂複合材及びその製造方法、並びに電界シールド材 |
JP2012229345A (ja) | 2011-04-27 | 2012-11-22 | Toray Ind Inc | 成形品 |
JP2016219466A (ja) * | 2015-05-14 | 2016-12-22 | トヨタ紡織株式会社 | 電磁波シールド材 |
JP2020526029A (ja) * | 2017-09-30 | 2020-08-27 | シーアールアールシー チンタオ シーファン カンパニー,リミティッド | ニッケルめっき炭素繊維膜、その製造方法、シールド構造及びその作製方法 |
JP2021021249A (ja) | 2019-07-29 | 2021-02-18 | 壮太 木村 | ドアガードクッション |
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