Manufacturing method of magnetic member and magnetic member

Abstract

To provide a method for manufacturing a thinner magnetic member in which a magnetic member that has sufficient interlayer strength between a substrate and a magnetic layer, and a magnetic member manufactured by the manufacturing method which is thin and hard to be broken if bent.SOLUTION: A method for manufacturing a magnetic member further comprises: a step of preparing a substrate which has a surface and a rear face, and on the surface of which an anchor coat layer is formed; a step of adhering a reinforcing member on the rear face of the substrate; a step of forming a composite magnetic layer, in which magnetic powder is dispersed in binder, on the anchor coat layer; and a step of peeling the reinforcing member after forming the composite magnetic layer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a magnetic member and a magnetic member manufactured thereby. [Background technology]

[0002] Patent Document 1 discloses a first magnetic sheet (magnetic member) in which a magnetic layer made of a magnetic composite material is formed directly on a support, and a second magnetic sheet (magnetic member) in which a magnetic layer made of a magnetic composite material is formed on a support via an adhesive layer.

[0003] Patent Document 2 discloses a sheet-shaped magnetic shielding unit (magnetic member). This magnetic shielding unit includes a ferrite sheet and a protective member provided on the upper part of the ferrite sheet.

[0004] In the magnetic shielding unit of Patent Document 2, the protective member includes a base material and an adhesive layer formed on one surface of the base material. The base material is adhered to a ferrite sheet by means of the adhesive layer. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2004-031578 A [Patent Document 2] Special Publication No. 2019-503068 Summary of the Invention [Problem to be solved by the invention]

[0006] A sheet-shaped magnetic member is often bent according to the shape of an object when used. Therefore, if the magnetic layer is formed directly on the support, as in the first magnetic sheet disclosed in Patent Document 1, there is a risk that the magnetic layer will peel off from the support. In other words, a magnetic sheet in which the magnetic layer is formed directly on the support has a problem that the interlayer strength between the magnetic layer and the support tends to be insufficient.

[0007] On the other hand, the second magnetic sheet of Patent Document 1 and the magnetic shielding unit of Patent Document 2 are less likely to have the above problems. However, the adhesive layer needs to have a certain thickness, for example, 3 to 50 μm, to obtain sufficient adhesive strength. Therefore, the second magnetic sheet of Patent Document 1 and the magnetic shielding unit of Patent Document 2 have the problem that it is difficult to make them thinner.

[0008] The present invention aims to provide a method for manufacturing a magnetic member that has sufficient interlayer strength between a substrate and a magnetic layer and that can produce a thinner magnetic member, thereby providing a thin magnetic member that is less likely to break even when bent. [Means for solving the problem]

[0009] The present invention provides a first method for producing a magnetic member, comprising the steps of: A step of preparing a substrate having a front surface and a back surface and an anchor coat layer formed on the front surface; forming a composite magnetic layer on the anchor coat layer, the composite magnetic layer having magnetic powder dispersed in a binder; The present invention provides a method for producing a magnetic member comprising:

[0010] The present invention provides a method for producing a first magnetic member as a method for producing a second magnetic member, comprising the steps of: before forming the composite magnetic layer, attaching a reinforcing member to the back surface of the base material; After forming the composite magnetic layer, peeling off the reinforcing member. The present invention further provides a method for manufacturing a magnetic member comprising the steps of:

[0011] The present invention provides a third method for producing a magnetic member, which is a second method for producing a magnetic member, comprising the steps of: The reinforcing member has a front surface and a back surface, The surface of the reinforcing member is attached to the base material, A release agent is applied to the back surface of the reinforcing member. A method for manufacturing a magnetic component is provided.

[0012] The present invention provides a fourth method for producing a magnetic member, which is any one of the first to third methods for producing a magnetic member, The thickness of the anchor coat layer is 0.5 μm or more and less than 1 μm. A method for manufacturing a magnetic component is provided.

[0013] The present invention provides a fifth method for producing a magnetic member, which is any one of the first to fourth methods for producing a magnetic member, The anchor coat layer is made of a polyether resin or a polyester resin. A method for manufacturing a magnetic component is provided.

[0014] The present invention provides a first magnetic member, A magnetic member comprising a substrate, an anchor coat layer formed on the substrate, and a composite magnetic layer formed on the anchor coat layer, The thickness of the anchor coat layer is 0.5 μm or more and less than 1 μm. A magnetic member is provided.

[0015] The present invention provides a first magnetic member as the second magnetic member, The anchor coat layer is made of a polyether resin or a polyester resin. A magnetic member is provided. Effect of the Invention

[0016] According to the method for manufacturing a magnetic member of the present invention, a substrate having an anchor coat layer formed on its surface is used, and a composite magnetic layer is formed on the anchor coat layer, thereby making it possible to manufacture a magnetic member that is thinner than when an adhesive layer is used, while realizing sufficient interlayer strength between the magnetic layer and the substrate. Furthermore, according to the method for manufacturing a magnetic member of the present invention, a composite magnetic body in which magnetic powder is dispersed in a binder is used as the magnetic body, making it possible to manufacture a magnetic member with high flexibility. Thus, according to the present invention, a magnetic member that is thin and does not easily break even when bent can be provided. [Brief description of the drawings]

[0017] [Figure 1] 3 is a flowchart illustrating a method for manufacturing a magnetic member according to an embodiment of the present invention. [Diagram 2] FIG 2 is a cross-sectional view showing a substrate used in the method for producing the magnetic member of FIG 1. An anchor coat layer is formed on the surface of the substrate. [Diagram 3] 3 is a cross-sectional view showing a state in which a reinforcing member is attached to the rear surface of the base material in FIG. 2. [Figure 4] 4 is a cross-sectional view showing a state in which a composite magnetic layer is formed on the anchor coat layer of FIG. 3. [Diagram 5] 2 is a cross-sectional view showing a magnetic member manufactured by the magnetic member manufacturing method of FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] A method for manufacturing a magnetic member according to an embodiment of the present invention will be described with reference to FIGS.

[0019] First, a substrate 10 as shown in Fig. 2 is prepared (step S101). The substrate 10 has a front surface 102 and a back surface 104, and an anchor coat layer 20 is formed on the front surface 102. That is, the substrate 10 is a substrate 10 with an anchor coat layer 20.

[0020] A PET (polyethylene terephthalate) film can be used as the substrate 10. Alternatively, a composite film having a conductor layer provided on the back surface of a PET film can be used as the substrate 10. In this case, the conductor layer is adhered to the back surface of the PET film using an adhesive. The conductor layer is, for example, an aluminum foil or a copper foil.

[0021] In this embodiment, the size of the substrate 10 may be significantly larger than the actual product size. For example, the substrate 10 may be a long and wide film. The thickness of the substrate 10 is preferably as thin as possible, and for example, the thickness of a PET film may be 5 to 20 μm, for example, about 12 μm. The thickness of the conductor layer may be 1 to 15 μm, for example, about 7 μm.

[0022] In this embodiment, the anchor coat layer 20 is made of, for example, a polyether-based resin or a polyester-based resin. The material of the anchor coat layer 20 can be selected depending on the expected environment in which the magnetic member will be used. For example, if the magnetic material is required to have solvent resistance and mechanical strength, it is preferable to use a polyester-based resin as the material of the anchor coat layer 20. Furthermore, if the magnetic material is required to have water resistance, such as when the magnetic member is used in a high humidity environment, it is preferable to use a polyether-based resin as the material of the anchor coat layer 20.

[0023] It is preferable that the thickness of the anchor coat layer 20 is as thin as possible. For example, the thickness of the anchor coat layer 20 is preferably less than 1 μm. However, in order to satisfactorily form the composite magnetic layer 40 (see FIG. 4) described below, the anchor coat layer 20 needs to have a certain degree of thickness. For example, the thickness of the anchor coat layer 20 is preferably 0.5 μm or more.

[0024] Next, as shown in FIG. 3, the reinforcing member 30 is attached to the back surface 104 of the base material 10 (step S102). More specifically, the reinforcing member 30 has a front surface 302 and a back surface 304. In this embodiment, a release agent is applied to the back surface 304 of the reinforcing member 30, and the front surface 302 of the reinforcing member 30 is attached to the base material 10. More specifically, the reinforcing member 30 is attached to the back surface 104 of the base material 10 using an adhesive (not shown) applied to the front surface 302 or an adhesive tape (not shown) attached to the front surface 302. By using an appropriate adhesive or adhesive tape, the front surface 302 of the reinforcing member 30 has a slight adhesiveness to the back surface 104 of the base material 10, making it detachable. In particular, when a thin base material 10 is used, it may be difficult to handle it by itself, so it is desirable to use the reinforcing member 30 to facilitate its handling.

[0025] The reinforcing member 30 is, for example, a PET film. A release agent does not necessarily need to be applied to the rear surface 304 of the reinforcing member 30. However, in consideration of storage of the semi-finished product after the composite magnetic layer 40 is formed, it is desirable that a release agent be applied to the rear surface 304 of the reinforcing member 30. For example, in the case where the base material 10 is a long film, when the semi-finished product after the composite magnetic layer 40 described below is formed is wound in a roll and stored, the composite magnetic layer 40 can be prevented from adhering to the reinforcing member 30.

[0026] As described below, the reinforcing member 30 is removed in a later step. In other words, the reinforcing member 30 is not a component of the magnetic member manufactured by the method according to the present embodiment. Therefore, there is no particular limit to the thickness of the reinforcing member 30. However, it is preferable that the thickness of the reinforcing member 30 is as thin as possible. If the base material 10 has a necessary and sufficient strength, step S102 may be omitted and the reinforcing member 30 may not be provided.

[0027] 4, the composite magnetic layer 40 is formed directly on the anchor coat layer 20 (step S103). The composite magnetic layer 40 is formed by applying a coating liquid in which magnetic powder is dispersed in a binder, and then drying it. In more detail, a coating liquid in which soft magnetic powder, a binder, an organic solvent, a flame retardant, etc. are mixed is applied onto the anchor coat layer 20, and then dried. The coating liquid is applied so that the composite magnetic layer 40 has a thickness of 100 μm or less after drying.

[0028] Here, the soft magnetic powder is preferably magnetic stainless steel (Fe-Cr-Al-Si alloy), Fe-Si-Al alloy such as Sendust (registered trademark), permalloy (Fe-Ni alloy), silicon copper (Fe-Cu-Si alloy), Fe-Si alloy, Fe-Si-B(-Cu-Nb) alloy, Fe-Ni-Cr-Si alloy, Fe-Si-Cr alloy, Fe-Si-Al-Ni-Cr alloy, Mo-Ni-Fe, amorphous alloy, etc. Such soft magnetic powder may be used alone or in combination. In particular, metal alloys with large magnetization are desirable for improving the magnetic permeability characteristics. In addition, the shape of the soft magnetic powder is not particularly limited, but it is preferable that the powder is flat, and it is preferable that most of the flat-shaped soft magnetic powder in the composite magnetic layer 40 is aligned and arranged so as to be roughly parallel to the main surface of the composite magnetic layer 40.

[0029] As the binder, a polymer binder such as rubber, elastomer, or resin is preferable, and a thermoplastic resin is more preferable. In particular, EVA (ethylene-vinyl acetate copolymer resin), NBR (acrylonitrile butadiene rubber), nitrile rubber, ethylene-propylene-diene rubber, acrylic rubber, ethylene-vinyl acetate copolymer, silicone rubber, polyurethane, etc. are preferable.

[0030] 5, the reinforcing member 30 is peeled off (step S104). Note that, if step S201 is omitted, this step is not necessary.

[0031] As described above, a magnetic member is manufactured by the manufacturing method of the magnetic member according to the present embodiment. When the substrate 10 is a long and wide film, the manufactured magnetic member is cut according to the product size. For example, the manufactured magnetic member may be cut into a plurality of narrow long products.

[0032] As described above, according to this embodiment, the composite magnetic layer 40 is formed directly on the anchor coat layer 20 of the substrate 10. This makes it possible to reduce the thickness of the magnetic member while achieving sufficient interlayer strength between the substrate 10 and the composite magnetic layer 40. As a result, it is possible to obtain a magnetic member in which the composite magnetic layer 40 does not peel off even when bent and which is resistant to breakage.

[0033] Although the present invention has been described above with reference to the embodiment, the present invention is not limited to this. [Explanation of symbols]

[0034] 10 Base material 102 Surface 104 Back side 20 Anchor coat layer 30 Reinforcement member 302 Surface 304 Back side 40 Composite magnetic layer

Claims

1. A method for manufacturing a magnetic member, comprising the steps of: A step of preparing a substrate having a front surface and a back surface and an anchor coat layer formed on the front surface; forming a composite magnetic layer on the anchor coat layer, the composite magnetic layer having a magnetic powder dispersed in a binder; before forming the composite magnetic layer, attaching a reinforcing member to the back surface of the base material; After forming the composite magnetic layer, peeling off the reinforcing member. A method for manufacturing a magnetic member comprising the steps of:

2. A method for producing a magnetic member according to claim 1, comprising the steps of: The reinforcing member has a front surface and a back surface, The surface of the reinforcing member is attached to the base material, A release agent is applied to the back surface of the reinforcing member. A method for manufacturing a magnetic member.

3. A method for producing a magnetic member according to claim 1 or 2, comprising the steps of: The thickness of the anchor coat layer is 0.5 μm or more and less than 1 μm. A method for manufacturing a magnetic member.

4. A method for producing a magnetic member according to any one of claims 1 to 3, comprising the steps of: The anchor coat layer is made of a polyether resin or a polyester resin. A method for manufacturing a magnetic member.

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