Sheet-like magnetic member

Abstract

The invention provides a sheet-shaped magnetic member which can easily suppress reduction of magnetic shielding characteristics relative to a winding-shaped coil. This sheet-like magnetic member is provided with a plurality of magnetic segments which are formed in a long shape and have anisotropy such that the magnetic characteristics in the longitudinal direction differ from the magnetic characteristics in the width direction intersecting the longitudinal direction, and the plurality of magnetic segments are arranged in a radial pattern.

Description

[0001] Cross-reference to related applications

[0002] This international application claims priority based on Japanese Patent Application No. 2022-121759 filed with the Japan Patent Office on July 29, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to a sheet-like magnetic member used for a magnetic core, an inductor, a magnetic shield, and the like. Background Art

[0004] As a charging method, a non-contact charging method is widely used. The non-contact charging method is popular in electronic devices such as tablet information terminals, music players, smart phones, and mobile phones. In addition, the non-contact charging technology is a technology that can also be applied to electronic devices other than the above, electric vehicles, and drones. In addition, it is a technology that can also be applied to forklifts, AGV (Automated Guided Vehicle) and other transport vehicles, railways, trams, etc.

[0005] As a method for manufacturing a sheet-like magnetic member for a contactless charging method, there is known a method for manufacturing a sheet-like magnetic member for an inductor or a magnetic shield, etc. (for example, see Patent Document 1). The manufacturing method described in Patent Document 1 includes a step of bonding a thin plate-like magnetic body to a sheet substrate via an adhesive layer to form a sheet-like magnetic member, and a step of dividing the thin plate-like magnetic body into a plurality of pieces by an external force while maintaining the state where the thin plate-like magnetic body is bonded to the sheet substrate.

[0006] In addition, a combination of an amorphous alloy ribbon and a nanocrystalline alloy ribbon is known (for example, refer to Patent Document 2). In Patent Document 2, stacking of nanocrystalline ribbons is disclosed. Specifically, a structure in which nanocrystalline ribbons are arranged and stacked piece by piece is disclosed. The nanocrystalline ribbons are arranged in the transverse direction, corresponding to the width, and are also stacked in the longitudinal direction. It is disclosed that when the nanocrystalline ribbons are stacked, the length direction is oriented in different directions. It is disclosed that by stacking in this way, the effect of improving structural rigidity is achieved.

[0007] Prior art literature

[0008] Patent Literature

[0009] Patent Document 1: Japanese Patent Application Publication No. 2008-112830

[0010] Patent Document 2: Japanese Patent Application No. 2019-522355 Summary of the invention

[0011] Problems to be solved by the invention

[0012] As a sheet-like magnetic member used for non-contact charging, a sheet-like magnetic member with higher performance is required.

[0013] For example, in a non-contact charging circuit for an automobile, a large current may flow through the primary coil and the secondary coil. In order to cope with the flow of large current in the non-contact charging circuit for an automobile, a sheet-shaped magnetic component with a high shielding effect is required. In addition, in the case of a non-contact charging circuit for an automobile, a wide sheet-shaped magnetic component is desired.

[0014] As such a sheet-shaped magnetic member, a sheet-shaped magnetic member using a nanocrystalline alloy thin ribbon is preferable. Compared with other materials used for magnetic sheets, the nanocrystalline alloy thin ribbon has excellent magnetic properties and can be made thinner.

[0015] On the other hand, the nanocrystalline alloy ribbon has the problem that it is difficult to form a wide shape. In order to solve this problem, the nanocrystalline alloy ribbon is sometimes arranged to form a wide sheet-like magnetic component. For example, the long nanocrystalline alloy ribbon is sometimes arranged along the width direction to form a wide sheet-like magnetic component.

[0016] The nanocrystalline alloy thin strip formed into a strip shape sometimes has different magnetic properties in the length direction and the width direction orthogonal to the length direction depending on the manufacturing method. For example, there is a case where the magnetic properties in the length direction are better than the magnetic properties in the width direction, and conversely, the magnetic properties in the width direction are better than the magnetic properties in the length direction. In other words, the nanocrystalline alloy thin strip sometimes has anisotropy depending on the manufacturing method.

[0017] Regarding the coil characteristics of the primary coil and the secondary coil, the higher the Q1 value represented by the following formula (1), the lower the loss and the more excellent the characteristics are. By increasing the Q1 value, the charging efficiency of non-contact charging can be improved.

[0018] Q1=2πfLs / Rs…(1)

[0019] Where f is the frequency, Ls is the inductance of the coil, and Rs is the resistance of the coil.

[0020] In order to improve the characteristics of the coil, the characteristic required of the sheet-shaped magnetic member is a high Q2 value. The Q2 value is the ratio (μ' / μ") of the real part (μ') to the imaginary part (μ") of the complex magnetic permeability.

[0021] Fig.35 The correlation between the real part of the complex permeability (μ') and the Q2 value is shown in FIG. Fig.35 In the experiment, a ring core with an inner diameter of 8.6 mm and an outer diameter of 19.9 mm was punched out from a sheet-like magnetic member, and the measurement was performed using a BH analyzer SY-8218 manufactured by Iwasaki Communication Equipment Co., Ltd. at a frequency f of 85 kHz and a voltage V of 30 mV. Fig.35As shown, there is a tendency that the smaller the real part of the complex magnetic permeability (μ') is, the higher the Q2 value is.

[0022] In addition, in the state of the sheet-like magnetic component, the Q2 value in the length direction and the Q2 value in the width direction cannot be measured. In other words, the anisotropy of the sheet-like magnetic component cannot be measured. In addition, the arrangement of the sheet-like magnetic component cannot be determined based on the anisotropy.

[0023] The relative permeability (μr) of direct current has a good correlation with the real part (μ') of complex permeability. Therefore, the relative permeability (μr) of direct current can be measured, and the direction with low relative permeability (μr) of direct current is regarded as the direction with high Q2 value. Using the direction with high Q2 value thus obtained, the anisotropy of sheet-like magnetic components and the arrangement of sheet-like magnetic components can be determined.

[0024] When a sheet-shaped magnetic member is produced using such anisotropic nanocrystalline alloy ribbons, the characteristics of the sheet-shaped magnetic member may be unstable when the sheet-shaped magnetic member is used in a non-contact charging circuit due to the anisotropy of the nanocrystalline alloy ribbons.

[0025] Fig.36 It is a schematic diagram for explaining the arrangement relationship between the sheet-like magnetic member 250 and the primary coil 201 and the secondary coil 202 .

[0026] The sheet-like magnetic member 250 is arranged adjacent to at least one of the primary coil 201 and the secondary coil 202 included in the non-contact charging circuit. Fig.36 2 shows a state where the sheet-like magnetic member 250 and the secondary coil 202 are arranged adjacent to each other. The primary coil 201 is a coil arranged on the primary side of the contactless charging circuit, and the secondary coil 202 is a coil arranged on the secondary side. In the case where it is not necessary to identify the primary side and the secondary side, it is also referred to as a coil. The coil is formed by winding a conductor through which current flows into a spiral shape, and has a circular plate shape with a through hole in the center.

[0027] The current flows in the primary coil 201, and the flowing current generates a magnetic flux M. The magnetic flux M generated by the primary coil 201 flows toward the secondary coil 202 along the normal direction of the plate shape, for example, at the center of the primary coil 201. The magnetic flux flowing toward the secondary coil 202 flows from the inner periphery to the outer periphery of the coil. The magnetic flux M flowing toward the outer periphery flows in a direction returning to the primary coil 201 on the outer periphery side of the coil. The magnetic flux M returning to the primary coil 201 side flows from the outer periphery side to the inner periphery side.

[0028] The magnetic flux flowing toward the secondary coil 202 passes through the secondary coil 202. If the magnetic flux passing through the secondary coil 202 changes, a voltage is induced in the secondary coil 202 in accordance with the change in the magnetic flux. A current flows in the secondary coil 202 due to the induced voltage.

[0029] In the case where the sheet-like magnetic member has a structure in which anisotropic nanocrystalline alloy ribbons are arranged in the width direction as described above, the nanocrystalline alloy ribbons are arranged in a state in which the anisotropy is aligned in one direction. If the magnetic flux flows in the coil adjacent to the sheet-like magnetic member, the magnetic flux flows in a direction consistent with the anisotropy, that is, in a direction with a high Q2 value, in a part of the coil. In addition, in another part of the coil, the magnetic flux flows in a direction inconsistent with the anisotropy, that is, in a direction with a low Q2 value.

[0030] When the magnetic flux flows in a direction consistent with the anisotropy, the sheet-like magnetic member can easily exert magnetic shielding properties, greatly improving the Q1 value of the coil. On the other hand, when the magnetic flux flows in a direction inconsistent with the anisotropy, it is difficult to exert magnetic shielding properties, and the improvement of the Q1 value of the coil becomes small.

[0031] That is, when a sheet-shaped magnetic member formed by arranging anisotropic nanocrystalline alloy thin strips in the width direction is used to form a coil in a surrounding shape, there is a problem that the characteristics as a magnetic shield are difficult to stabilize and the characteristics are likely to deteriorate.

[0032] According to one aspect of the present disclosure, it is preferable to provide a sheet-shaped magnetic member that can easily suppress a decrease in magnetic shielding properties relative to a surrounding coil.

[0033] Methods for solving problems

[0034] The sheet-like magnetic member disclosed herein includes a plurality of elongated magnetic segments having anisotropic magnetic properties in the longitudinal direction and in the width direction intersecting the longitudinal direction, and the plurality of magnetic segments are arranged radially.

[0035] According to the sheet-like magnetic component disclosed in the present invention, it is easy to make the direction of the magnetic flux of the sheet-like magnetic component generated by the current flowing in the encircling coil used in combination with the sheet-like magnetic component consistent with the direction of the anisotropy of the sheet-like magnetic component. Specifically, it is easy to make the direction of the anisotropy in the magnetic segment, in other words, the direction of the low direct current relative magnetic permeability μr, that is, the direction of the high Q2 value and other directions with good magnetic properties consistent with the direction of the magnetic flux of the sheet-like magnetic component generated by the current flowing in the encircling coil.

[0036] Effects of the Invention

[0037] According to the sheet-like magnetic component disclosed in the present invention, by arranging the magnetic segments in a radial manner in the direction of anisotropy, it is easy to make the direction of the magnetic flux flowing in the encircling coil consistent with the anisotropy of the sheet-like magnetic component, and it is easy to suppress the reduction of the magnetic shielding characteristics of the encircling coil. In addition, according to the sheet-like magnetic component disclosed in the present invention, the effect of improving the characteristics of the combined coil is achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a top view explaining the structure of the magnetic sheet in this disclosure.

[0039] In Figure 2, Figure 2A is a diagram illustrating the shape and arrangement of magnetic segments, Figure 2B It is a diagram for explaining another arrangement of magnetic segments.

[0040] In Figure 3, Figure 3A 1 is a diagram illustrating a state before a long magnetic segment is cut into a triangular shape. Figure 3B This is a diagram for explaining a state after a long magnetic segment is cut into a triangular shape.

[0041] Figure 4 It is a partial side view explaining the stacked structure of the magnetic sheets.

[0042] Figure 5 It is a diagram for explaining the casting direction of radially arranged magnetic segments.

[0043] Figure 6 is a graph illustrating the correlation between the maximum deviation angle and the Q2 value.

[0044] In Figure 7, Fig. 7A 1 is a diagram illustrating a state before a long strip-shaped magnetic segment is cut into a notched triangular shape. Figure 7B 1 is a diagram illustrating a state after a long strip-shaped magnetic segment is cut into a notched triangular shape. Figure 7C This is a diagram for explaining a state where two notched triangular-shaped magnetic segments are arranged radially.

[0045] In Figure 8, Fig. 8A 1 is a diagram illustrating a state before a long strip-shaped magnetic segment is cut into a notched triangular shape. Figure 8B 1 is a diagram illustrating a state after a long strip-shaped magnetic segment is cut into a notched triangular shape. Figure 8C This is a diagram for explaining a state where two notched triangular-shaped magnetic segments are arranged radially.

[0046] In Figure 9, Fig.9A This is a diagram illustrating the state before the long strip-shaped magnetic segment is cut into two triangular shapes. Fig. 9BThis is a diagram illustrating the state after the long strip-shaped magnetic segment is cut into two triangular shapes. Fig. 9C This is a diagram for explaining a state where two types of triangular magnetic segments are radially arranged.

[0047] In Figure 10, Fig. 10A This is a diagram illustrating a state before a plurality of long strip-shaped magnetic segments are cut into fan-shaped segments. Fig. 10B The figure shows the magnetic segments after being cut into sectors.

[0048] Fig.11 It is a top view explaining the structure of the magnetic sheet having a circular shape.

[0049] Fig.12 It is a description of the composition Fig.11 A top view of the shape of the magnetic segments of the magnetic sheet.

[0050] Fig.13 It is a top view explaining another structure of the magnetic sheet.

[0051] Fig.14 It is a description of the composition Fig.13 A top view of the shape of the magnetic fragments in the shape of long strips of magnetic sheets.

[0052] Fig.15 This is a partially enlarged view for explaining the structure of a magnetic sheet formed by stacking a plurality of magnetic segments.

[0053] Fig.16 The diagram is a diagram for explaining a method of forming a regular triangle-shaped magnetic segment and a right-angled triangle-shaped magnetic segment from a plurality of long strip-shaped magnetic segments.

[0054] Fig.17 It is a figure explaining the structure of the octagonal magnetic sheet.

[0055] Fig.18 It is explained in Fig.17 A diagram showing a state in which a covering magnetic segment is arranged on a magnetic sheet.

[0056] Fig.19 This is a schematic diagram for explaining a method for producing a long magnetic sheet.

[0057] Fig. 20 It is a cross-sectional view explaining the structure of the stacked body supplied from the first unwinding roll.

[0058] Fig.21 This is a cross-sectional view for explaining the structure of a laminated body from which a resin sheet is supplied from a first unwinding roll and peeled off.

[0059] Fig. 22 It is a cross-sectional view for explaining the structure of the magnetic ribbon supplied from the second unwinding roller.

[0060] Fig.23 It is a cross-sectional view explaining a state where the magnetic thin tape is bonded to the adhesive layer by the bonding roller.

[0061] Fig.24 This is a cross-sectional view for explaining a state in which cracks are formed in a magnetic ribbon by a cracking roller.

[0062] Fig.25 This is a schematic diagram for explaining a method for producing a long magnetic sheet.

[0063] Fig.26 It is a figure explaining the structure of the magnetic sheet of Example 1.

[0064] Fig. 27 This is a diagram for explaining the structure of the magnetic sheet of Example 2.

[0065] Fig.28 This is a diagram for explaining the structure of the magnetic sheet of Example 3.

[0066] Fig.29 It is a figure explaining the structure of the magnetic sheet of Example 4.

[0067] Fig.30 It is a diagram for explaining the structure of the magnetic sheet of Comparative Example 1.

[0068] Fig.31 It is a figure explaining the measuring device for evaluating a magnetic sheet.

[0069] Fig.32 It is a graph showing the value of Q1 calculated based on the measurement results.

[0070] Fig.33 It is a graph showing the measured value of Ls.

[0071] Fig.34 It is a graph showing the measured Rs value.

[0072] Fig.35 It is a graph showing the correlation between the real part of complex magnetic permeability (μ') and the Q2 value.

[0073] Fig.36 This is a diagram for explaining a state in which a sheet-like magnetic member and a coil are arranged adjacent to each other.

[0074] Description of Reference Numerals

[0075] 10…adhesive layer, 20…magnetic thin tape, 110…magnetic sheet (sheet-shaped magnetic member), 120T, 120S…magnetic segments, 151…first adjacent position, 152…second adjacent position. DETAILED DESCRIPTION

[0076] One side reference Figures 1 to 34The magnetic sheet 110 (corresponding to an example of a sheet-like magnetic member) according to one embodiment of the present disclosure will be described. The magnetic sheet 110 is used in a non-contact charging device. The magnetic sheet 110 can be used in a power supply device of the charging device or in a power receiving device.

[0077] In this embodiment, an example of using the magnetic sheet 110 for contactless charging of a device that consumes more power than an information processing device and / or an electronic device (e.g., a smartphone, etc.) is described. Specifically, an example of using the magnetic sheet 110 for contactless charging of a moving object such as a car is described. The magnetic sheet 110 can also be applied to transport vehicles such as forklifts and AGVs, railways, trams, etc.

[0078] Figure 1 It is a top view explaining the structure of the magnetic sheet 110 .

[0079] like Figure 1 As shown in FIG. 1 , the magnetic sheet 110 is a plate-shaped member. Figure 1 The magnetic sheet 110 is disposed adjacent to the coil 200 for contactless charging in a direction perpendicular to the paper surface. The magnetic sheet 110 is preferably used in combination with the coil 200 .

[0080] The coil 200 is a member in which a conducting wire through which current flows is wound in a spiral shape, and the coil 200 has a circular shape with a through hole in the center where no conducting wire is arranged. Figure 1 In the figure, only the shape of the coil 200 is indicated by a dotted line for easy understanding of the magnetic sheet 110. The coil 200 is circular, but the magnetic sheet 110 may be used in combination with a coil having a shape other than a circular shape, such as a rectangular coil.

[0081] The coil 200 may be a primary-side coil or a secondary-side coil in contactless charging. In the present embodiment, an example in which the coil 200 is a secondary-side coil will be described.

[0082] The magnetic sheet 110 has a structure in which a plurality of magnetic segments 120T are arranged radially. Figure 1 , the magnetic sheet 110 is shown in which 32 magnetic segments 120T are arranged radially. The number of magnetic segments 120T included in the magnetic sheet 110 may be less than 32 or more than 32.

[0083] The circular coil 200 is arranged to share the center with the magnetic sheet 110. Specifically, the radial center of the magnetic sheet 110 is shared with the center of the circular coil 200. The "shared" mentioned here includes not only the case where the two centers coincide with each other, but also the case where the two centers fall within a predetermined range.

[0084] For example, the above-mentioned predetermined range may be a state in which the center of the magnetic sheet 110 falls inside the inner diameter of the coil 200 .

[0085] The above-mentioned predetermined range may be within the shorter range of 20% or less of the outer diameter of coil 200 or 5% of half of the difference between the outer diameter of magnetic sheet 110 and the outer diameter of coil 200 .

[0086] exist Figure 1 In the embodiment, the center portion of the magnetic sheet 110 is likely to have a structure in which a plurality of magnetic segments 120T overlap each other. Therefore, there is a situation in which the center portion bulges and the workability is deteriorated. In order to improve this, the center portion of the magnetic sheet 110 may also be provided with a hole structure. In this case, the hole is provided to be smaller than the inner diameter of the coil 200.

[0087] It should be noted that the hole may be drilled after the magnetic sheet 110 is formed, or a portion serving as the hole may be pre-set on the magnetic sheet 120T.

[0088] Figure 2A It is a description of the composition Figure 1 FIG. 1 is a diagram showing an example of the shape and arrangement of the magnetic segment 120T of the magnetic sheet 110, Figure 2B 120T is a diagram for explaining another arrangement of the magnetic segments 120T.

[0089] like Figure 2A As shown, the magnetic segment 120T has a triangular shape having a long side 121, a short side 122, and a hypotenuse 123. In other words, the magnetic segment 120T has a shape in which the width increases from the angle side formed by the long side 121 and the hypotenuse 123, that is, one end side, toward the short side 122 side, that is, the other end side. In this embodiment, an example in which the magnetic segment 120T has a right triangle shape is described. It should be noted that the magnetic segment 120T may also have a triangular shape other than a right triangle.

[0090] In the magnetic sheet 110, a group of two magnetic segments 120T whose long sides 121 are adjacent to each other is arranged radially. In other words, the two magnetic segments 120T are arranged radially as a group having an isosceles triangle shape. Figure 1 Magnetic sheet 110 including a group of 16 groups of magnetic segments 120T is shown in FIG.

[0091] When two magnetic segments 120T are arranged so that their long sides 121 are adjacent to each other and when a group of two magnetic segments 120T is arranged radially, the magnetic segments 120T may be arranged overlappingly, butted against each other, or arranged with a gap between the magnetic segments 120T. In this embodiment, the magnetic segments 120T are butted against each other.

[0092] It should be noted that the group of magnetic segments 120T can be as follows: Figure 2A The groups of long sides 121 shown as adjacent to each other may also be as follows Figure 2B The long sides 121 and the oblique sides 123 are shown as groups adjacent to each other.

[0093] Figure 3A and Figure 3B This is a diagram for explaining a method of forming the magnetic segment 120T from a long strip shape to a triangular shape.

[0094] The triangular shaped magnetic segment 120T is composed of Figure 3A The magnetic segment 120S having a long strip shape with a long side 121 and a short side 122 is formed. In this embodiment, an example in which the length 121L of the long side 121 is 150 mm and the length 122S of the short side 122 is 30 mm is described. It should be noted that the length 121L may be longer or shorter than 150 mm. In addition, the length 122S may be longer or shorter than 30 mm.

[0095] The triangular magnetic segment 120T is formed by cutting along the diagonal line connecting two diagonally opposite corners of the long strip-shaped magnetic segment 120S, that is, the cutting line 24. Two triangular magnetic segments 120T are formed from one long strip-shaped magnetic segment 120S. The length 121L of the long side 121 and the length 122S of the short side 122 of the formed triangular magnetic segment 120T are the same as the length 121L of the long side 121 and the length 122S of the short side 122 of the long strip-shaped magnetic segment 120S.

[0096] Figure 4 FIG. 1 is a partial side view illustrating the stacked structure of the magnetic segments 120T.

[0097] The magnetic segment 120T has a multilayer structure in which a plurality of adhesive layers 10 and a plurality of magnetic thin strips 20 are alternately stacked. Figure 4 As shown, an example of a multilayer structure having six adhesive layers 10 and five magnetic thin tapes 20 alternately stacked will be described.

[0098] Specifically, it has a multilayer structure in which an adhesive layer 10 , a magnetic thin ribbon 20 , an adhesive layer 10 , a magnetic thin ribbon 20 , an adhesive layer 10 , a magnetic thin ribbon 20 , an adhesive layer 10 , a magnetic thin ribbon 20 , an adhesive layer 10 , a magnetic thin ribbon 20 , and an adhesive layer 10 are stacked in this order.

[0099] It should be noted that the number of magnetic thin ribbons 20 included in the magnetic segment 120T may be 5 layers as described above, or may be any number of layers other than 5 layers, 2 layers or more. The number of magnetic thin ribbons 20 is preferably 3 layers or more, preferably 4 layers or more. In addition, the number of magnetic thin ribbons 20 may be 20 layers or more, but preferably 20 layers or less. It should be noted that the number of magnetic thin ribbons 20 is further preferably 15 layers or less, and more preferably 10 layers or less.

[0100] In addition, the magnetic segments 120T can be further stacked to form the magnetic sheet 110. In this case, the number of layers of the magnetic thin strips 20 in the magnetic sheet 110 is greater than the number of layers of the magnetic segments 120T. For example, the number of layers of the magnetic thin strips in the magnetic sheet 110 is 30 to 200. It may be less than 30 layers or more than 200 layers.

[0101] Furthermore, it is preferable that the magnetic segments 120T are stacked so as to be shifted when viewed in the stacking direction, and the magnetic gaps between the magnetic segments 120T are discontinuous in the stacking direction.

[0102] Two layers of resin sheets 15 may be further provided in the magnetic segment 120T. The two layers of resin sheets 15 are respectively bonded to the two outermost adhesive layers 10 in the magnetic segment 120T. It should be noted that the resin sheet 15 may not be provided in the magnetic segment 120T. The magnetic thin strip 20 may also be exposed. In addition, at least one of an amorphous alloy thin strip, a nanocrystalline alloy thin strip, other magnetic materials, and a metal foil such as aluminum may be attached instead of the resin sheet 15.

[0103] In addition, a resin sheet may be provided on the upper surface and the lower surface of the magnetic sheet 110. The resin sheet can also be used as a base material when the magnetic segments 120T are arranged, and can also be used as a protective sheet.

[0104] like Figure 4 As shown, the adhesive layer 10 is a member to which the magnetic thin tape 20 is attached. The adhesive layer 10 is a member formed in a film shape. A support 11 and an adhesive 12 are provided on the adhesive layer 10.

[0105] The support body 11 is a member formed in a film shape. The support body 11 is formed using a flexible resin material. As the resin material, polyethylene terephthalate (PET: Polyethylene terephthalate) can be used.

[0106] The adhesive 12 is provided in a film or layer form on the first surface 11A and the second surface 11B of the support 11 .

[0107] The adhesive 12 may be, for example, a pressure-sensitive adhesive. For example, a known adhesive such as an acrylic adhesive, a silicone adhesive, a urethane adhesive, a synthetic rubber, or a natural rubber may be used as the adhesive 12. Acrylic adhesives are preferred as the adhesive 12 because they are excellent in heat resistance and moisture resistance and can bond a wide range of materials. In the present embodiment, an example in which the adhesive 12 is provided on the entire surface of the first surface 11A and the second surface 11B of the support 11 is described.

[0108] The magnetic ribbon 20 is a ribbon formed of a magnetic material. A crack 21 is formed in the magnetic ribbon 20. The magnetic ribbon 20 is divided into a plurality of small pieces 22 by the crack 21. In other words, the magnetic ribbon 20 includes a plurality of small pieces 22. The crack 21 refers to a magnetic gap formed in the magnetic ribbon 20, for example, a crack and / or a fissure including the magnetic ribbon 20.

[0109] By forming cracks 21 in magnetic ribbon 20, it is easy to improve the Q2 value when magnetic sheet 110 is used as a magnetic body for inductor. In addition, when magnetic sheet 110 is used as a magnetic shield, it is easy to break the current path of magnetic ribbon 20 and reduce eddy current loss.

[0110] As a material forming the magnetic ribbon 20, an alloy composition of Fe-based or Co-based alloy, a nanocrystalline alloy or an amorphous alloy can be used. The magnetic ribbon 20 is particularly preferably a ribbon formed of a nanocrystalline alloy (hereinafter also referred to as a "nanocrystalline alloy ribbon").

[0111] As the nanocrystalline alloy ribbon, a nanocrystalline alloy ribbon obtained by heat-treating a nanocrystalline amorphous alloy ribbon capable of nanocrystallization can be used. During the heat treatment of nanocrystallization, it is preferred to perform the heat treatment of nanocrystallization under a state where tension is applied to the amorphous alloy ribbon capable of nanocrystallization. It should be noted that the ribbon formed with the amorphous alloy as the material is also referred to as an amorphous alloy ribbon or an amorphous alloy ribbon.

[0112] The nanocrystalline alloy ribbon preferably has a composition represented by the following general formula.

[0113] General formula: (Fe 1-a M a ) 100-x-y-z-α-β-γ Cu x Si y B z M' α M” β X γ (atom%)

[0114] In the above general formula, M is Co and / or Ni, M' is at least one element selected from the group consisting of Nb, Mo, Ta, Ti, Zr, Hf, V, Cr, Mn and W, M" is at least one element selected from the group consisting of Al, platinum group elements, Sc, rare earth elements, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, α, β and γ satisfy 0≤a≤0.5, 0.1≤x≤3, 0≤y≤30, 0≤z≤25, 5≤y+z≤30, 0≤α≤20, 0≤β≤20 and 0≤γ≤20, respectively.

[0115] Preferably, in the above general formula, a, x, y, z, α, β and γ are 0≤a≤0.1, 0.7≤x≤1.3, 12≤y≤17, 5≤z≤10, 1.5≤α≤5, 0≤β≤1 and 0≤γ≤1, respectively.

[0116] In this embodiment, the magnetic thin strip 20 is an example of a thin strip of Fe-Cu-Nb-Si-B nanocrystalline alloy (FT-3 manufactured by Bomarican Co., Ltd. (formerly Hitachi Metals, Ltd.)). It should be noted that the magnetic thin strip 20 can be a nanocrystalline alloy thin strip having other compositions represented by the above general formula, or it can be an amorphous alloy thin strip.

[0117] When the magnetic ribbon 20 is a nanocrystalline alloy ribbon, it is mechanically more fragile than when the magnetic ribbon 20 is an amorphous alloy ribbon. When the magnetic ribbon 20 is a nanocrystalline alloy ribbon, when an external force is directly applied to the magnetic ribbon 20 to form the crack 21, the crack 21 can be formed with a smaller external force.

[0118] In the case where the magnetic ribbon 20 is a nanocrystalline alloy ribbon, the cracks 21 can be formed without substantially forming irregularities on the surface of the magnetic ribbon 20. Therefore, the planar state of the magnetic ribbon 20 can be made into a good state. The temporal change of the shape of the magnetic ribbon 20 generated after the magnetic ribbon 20 and the adhesive layer 10 are bonded to form the magnetic segment 120T and the magnetic sheet 110 is reduced. The temporal change of the magnetic properties of the magnetic segment 120T and the magnetic sheet 110 can be suppressed.

[0119] As the magnetic thin strip 20, for example, an alloy thin strip having a thickness of 100 μm or less manufactured by roll quenching can be used. The thickness of the magnetic thin strip 20 is preferably 50 μm or less, more preferably 30 μm or less, further preferably 25 μm or less, and particularly preferably 20 μm or less. In addition, if the thickness is thin, it becomes difficult to handle the magnetic thin strip 20, so the thickness of the magnetic thin strip 20 is preferably 5 μm or more, more preferably 10 μm or more.

[0120] The magnetic ribbon 20, which is a nanocrystalline alloy ribbon, is obtained by manufacturing an amorphous alloy ribbon and then performing a heat treatment to generate nanocrystals. The magnetic ribbon 20 may have anisotropy of magnetic properties due to the manufacturing method.

[0121] In addition, in order to reduce the DC relative magnetic permeability (μr) of the magnetic thin strip 20, there is a method of reducing the size of the crack 21. In addition, there is a method of imparting anisotropy to the amorphous alloy thin strip by heat-treating the amorphous alloy thin strip in a magnetic field and applying tension during the heat treatment of the amorphous alloy thin strip, thereby reducing only the DC relative magnetic permeability (μr) in a specified direction.

[0122] For example, in a method for producing a nanocrystalline alloy ribbon by continuously conveying a long amorphous alloy ribbon while bringing it into contact with a heating body and subjecting it to heat treatment, the magnetic properties may be different in the length direction of the long ribbon and in the width direction orthogonal to the length direction. Figure 3A In the illustrated strip-shaped magnetic segment 120S, the direction in which the long sides 121 extend is the same as the longitudinal direction of the strip, and the direction in which the short sides 122 extend is the same as the width direction orthogonal to the longitudinal direction.

[0123] In the present embodiment, an example is described in which the magnetic properties in the length direction (the direction in which the long side 121 extends) of the magnetic strip 20 are superior to the magnetic properties in the width direction. The length direction of the magnetic strip 20 is the same direction as the casting direction. The casting direction refers to the direction produced when casting the magnetic strip 20. Specifically, it is the direction along the rotation direction of the cooling roller when the molten metal forming the magnetic strip 20 is discharged to the cooling roller for casting. It should be noted that the magnetic properties in the width direction of the magnetic strip 20 may also be superior to the magnetic properties in the length direction.

[0124] Figure 5 1 is a diagram for explaining the casting direction of the radially arranged magnetic segments 120T. It should be noted that the casting direction is the same as the anisotropic direction (the direction with a high Q2 value).

[0125] like Figure 5 As shown, the casting directions of the groups of two magnetic segments 120T whose long sides 121 are adjacent to each other are the same. In the groups of radially arranged magnetic segments 120T, the difference in casting direction between the groups of adjacent magnetic segments 120T is an angle α.

[0126] The magnetic flux generated by the circular coil 200 flows in the magnetic sheet 110 in a direction perpendicular to the winding direction of the coil 200 (the direction of the wire of the coil). In other words, the direction in which the magnetic flux flows in the magnetic sheet 110 is the magnetic flux direction (see Figure 5) becomes a direction perpendicular to the winding direction of the coil 200 (the direction of the wire of the coil). In addition, in the magnetic segment 120T, the magnetic flux direction changes between the direction extending from the long side 121 to the direction extending from the oblique side 123. It should be noted that, in other words, the magnetic flux direction in the magnetic sheet 110 becomes a radial direction from the central part of the magnetic sheet 110 (corresponding to the central part of the coil 200) toward the periphery.

[0127] The offset angle between the casting direction of the magnetic segment 120T, in other words, the direction with high Q2 value (also referred to as high Q direction) and the magnetic flux direction is the largest when the magnetic flux direction is the direction in which the oblique side 123 extends. The largest offset angle (also referred to as maximum offset angle) is α / 2.

[0128] Figure 6 is a graph illustrating the correlation between the maximum deviation angle and the Q2 value. Figure 6 In the figure, the horizontal axis is the maximum deviation angle α / 2 (°), and the vertical axis is the Q2 value.

[0129] exist Figure 6 In FIG. 1 , it is shown that the Q2 value tends to increase as the maximum offset angle α / 2 decreases. In other words, it is shown that the magnetic flux flows in a direction consistent with the anisotropy and the magnetic sheet 110 tends to exhibit magnetic shielding properties.

[0130] The angle α is preferably 120° or less, more preferably 90° or less, and even more preferably 45° or less. In order to manufacture the magnetic segment 120T or the magnetic sheet 110 , the angle α is preferably 5° or more, and more preferably 10° or more.

[0131] In the above, the relationship between the direction of the anisotropy of the magnetic segment 120T (casting direction) and the direction of the magnetic flux in the magnetic segment 120T is explained. In other words, it can be explained by the relationship between the direction of the current in the coil (the direction of the conductor of the coil) and the direction of the anisotropy of the magnetic strip (magnetic segment) (casting direction).

[0132] That is, it can be said that the best relationship is that the direction of the anisotropy of the magnetic thin strip (magnetic segment 120T) and the direction of the current of the coil facing the magnetic thin strip (the direction of the conductor of the coil) are orthogonal.

[0133] As described above, the magnetic sheet is formed by combining a plurality of magnetic segments, and the magnetic segments are formed by magnetic thin strips. The direction of the anisotropy of each magnetic thin strip and the direction of the current of the coil opposite to the magnetic thin strip (the direction of the conductor of the coil) are in a cross relationship, and the angle of the cross is preferably 30° or more. Preferably, it is 45° or more, and more preferably 67.5° or more. The closer the angle is to 90°, the more preferred.

[0134] It should be noted that the coil facing the magnetic thin strip also has a non-linear portion. In this case, the tangent direction of the coil in the central portion of each magnetic thin strip can be set as the direction of the coil current (the direction of the coil conductor).

[0135] In addition, the above description describes the relationship between the direction of the current of the coil (the direction of the conductor of the coil) and the direction of the anisotropy of the magnetic thin strip (the casting direction). In other words, the description can be made by the relationship between the direction of the anisotropy of the magnetic thin strip and the angle formed by the normal line of the relative coil. Moreover, in the present disclosure, the angle formed by the direction of the anisotropy of the magnetic thin strip and the normal line of the relative coil can be 60° or less.

[0136] The normal line of the coil varies according to the position in the coil. At any part of the coil, the sheet-like magnetic member can be formed in such a way that the angle formed by the normal line of the coil and the direction of the anisotropy of the magnetic thin strip relative to the coil is within 60°. It is preferably less than 45°, more preferably less than 22.5°. The closer the angle is to 0°, the more preferred.

[0137] Here, the term "the magnetic thin ribbon and the coil are opposite to each other" means that when the magnetic thin ribbon and the coil are transparently observed in the axial direction of the coil (a direction perpendicular to the plane of the magnetic sheet), the magnetic thin ribbon and the coil have an overlapping portion, and the overlapping portion is an opposite portion.

[0138] The magnetic thin tape 20 is bonded to the adhesive 12 of the adhesive layer 10 . In the present embodiment, the magnetic thin tape 20 is bonded to the adhesive 12 provided on the first surface 11A of the adhesive layer 10 .

[0139] The resin sheet 15 is a film-shaped member formed of resin and is also referred to as a protective film, a release film, or a gasket. The resin sheet 15 is a member for protecting the magnetic ribbon 20 , the magnetic segments 120S, the magnetic segments 120T, and the magnetic sheet 110 .

[0140] The resin sheet 15 has the function of suppressing the unnecessary increase of the cracks 21 (or cracks connecting a plurality of cracks 21 to form a mesh) described later due to the application of unexpected external force to the magnetic thin strip 20. In addition, it has the function of suppressing the small pieces 22 of the magnetic thin strip 20 from falling off and the function of suppressing the magnetic thin strip 20 from rusting.

[0141] The resin sheet 15 has a function of suppressing unnecessary deformation when processing the magnetic segments 120S, 120T, and the magnetic sheet 110 into a predetermined shape. Examples of unnecessary deformation include surface irregularities.

[0142] The resin sheet 15 is preferably a film-shaped member formed of resin, more preferably a member formed of elastic resin. If the resin sheet 15 is a member formed of resin, the elastic force of the resin sheet 15 can easily suppress the occurrence of unevenness on the surface of the magnetic ribbon 20.

[0143] Even if irregularities are formed on the surface of the magnetic thin strip 20, the irregularities of the magnetic thin strip 20 are easily flattened due to the elastic force of the resin sheet 15. The planar state of the magnetic thin strip 20 can be made into a good state with few irregularities. It is easy to reduce the temporal change of the magnetic properties of the magnetic segment 120T and the magnetic sheet 110.

[0144] The resin sheet 15 may use a resin having a lower limit of tensile elastic modulus of 0.1 GPa. If the tensile elastic modulus of the resin is 0.1 GPa or more, the above-mentioned effect can be easily obtained. The lower limit of the tensile elastic modulus is preferably 0.5 GPa, and more preferably 1.0 GPa.

[0145] The upper limit of the tensile modulus of the resin is preferably set to 10 GPa. If it is greater than 10 GPa, the deformation of the alloy ribbon may be inhibited when the crack 21 described later is formed. The upper limit of the tensile modulus is preferably 9 GPa, and more preferably 8 GPa.

[0146] The thickness of the resin sheet 15 is preferably 1 μm or more and 100 μm or less. If the thickness of the resin sheet 15 increases, the magnetic segments 120S, 120T, and the magnetic sheet 110 are less likely to deform. It is sometimes difficult to arrange the magnetic segments 120S, 120T, and the magnetic sheet 110 along a curved surface or a bent surface.

[0147] If the thickness of the resin sheet 15 is less than 1 μm, the resin sheet 15 is easily deformed. The handling of the resin sheet 15 becomes difficult, and the function of the resin sheet 15 to support the magnetic thin strip 20 may not be fully obtained. In the case where the resin sheet 15 is a protective film, the strength of the resin sheet 15 may be weakened, and the function of protecting the magnetic thin strip 20 may become insufficient.

[0148] In the resin sheet 15, as the resin, for example, polyethylene terephthalate (PET), polyimide, polyetherimide, polyethylene naphthalate, polypropylene, polyethylene, polystyrene, polycarbonate, polysulfone, polyetherketone, polyvinyl chloride, polyvinyl alcohol, fluororesin, acrylic resin, cellulose, etc. can be used. From the viewpoint of heat resistance and dielectric loss, polyamide and polyimide are particularly preferred as the resin forming the resin sheet 15.

[0149] 7A to 7C This is a diagram for explaining a method of forming the magnetic segment 120T from a rectangular shape to a trapezoidal shape.

[0150] It should be noted that the magnetic segment 120T may have a triangular shape as described above, or may have a trapezoidal shape. 7A to 7C As shown, the magnetic segment 120T having a trapezoidal shape may also be formed by the magnetic segment 120S having a long strip shape.

[0151] like Fig. 7A and Figure 7C As shown, the trapezoidal magnetic segment 120T is formed by cutting along the cutting line 24, which intersects with the two short sides 122 of the long magnetic segment 120S and intersects with the two corners located at the diagonal positions. Figure 7B As shown, the short side 122 corresponds to the upper base or the lower base of the trapezoidal-shaped magnetic segment 120T.

[0152] like Figure 7C As shown, the two trapezoidal magnetic segments 120T are arranged in a group with their long sides 121 adjacent to each other. The magnetic sheet 110 may be formed by arranging the group in a radial pattern.

[0153] FIG. 8A to FIG. 8C This is a diagram for explaining a method of forming the magnetic segment 120T from a rectangular shape to a notched triangular shape.

[0154] In addition, the magnetic segment 120T may also have a notched triangular shape. FIG. 8A to FIG. 8C As shown, the magnetic segment 120T having a notched triangular shape may be formed by the long strip-shaped magnetic segment 120S.

[0155] like Fig. 8A and Figure 8C As shown, the notched triangular magnetic segment 120T is formed by cutting along a cutting line 24 that intersects the two long sides 121 of the long magnetic segment 120S and intersects near two diagonally located corners.

[0156] like Figure 8C As shown, the two notched triangular magnetic segments 120T are arranged in a group with the long sides 121 adjacent to each other. The group may be arranged radially to form the magnetic sheet 110 .

[0157] 9A to 9C The diagrams are for explaining a method of forming the magnetic segment 120T from a long strip shape to two types of triangular shapes.

[0158] In addition, the magnetic segment 120T may also include two triangular-shaped magnetic segments 120Ta and 120Tb. 9A to 9CAs shown, the magnetic segments 120Ta and 120Tb having a notched triangular shape may be formed by the long strip-shaped magnetic segment 120S.

[0159] like Fig.9A and Fig. 9C As shown, the magnetic segment 120Ta and the magnetic segment 120Tb are formed by cutting the long magnetic segment 120S along two cutting lines 24. The two cutting lines 24 are lines extending from the center of the short side 122 of the long magnetic segment 120S toward two opposing corners.

[0160] The magnetic segment 120Ta has an isosceles triangle shape having one short side 122 and two hypotenuses 123a. The magnetic segment 120Tb has a right triangle shape having one long side 121, one short side 122b and one hypotenuse 123a.

[0161] like Fig. 9C As shown, one magnetic segment 120Ta and two magnetic segments 120Tb formed by one long strip-shaped magnetic segment 120S are arranged in a group. Specifically, the magnetic segment 120Ta is arranged between the two magnetic segments 120Tb. In addition, the oblique side 123a of the magnetic segment 120Ta is arranged adjacent to the long side 121 of the magnetic segment 120Tb. The group can also be arranged radially to form the magnetic sheet 110.

[0162] Fig. 10A and Fig. 10B This is a diagram for explaining a method of forming one magnetic segment 120T from a long strip shape in which three magnetic segments 120S are arranged.

[0163] The magnetic segment 120T having a fan-shaped shape may be formed by a plurality of magnetic segments 120S. Fig. 10A and Fig. 10B An example is shown in which one magnetic segment 120T is formed by three magnetic segments 120S. The number of the long magnetic segments 120S forming one magnetic segment 120T may be two or four or more.

[0164] When a plurality of magnetic segments 120S are arranged to form a long strip, for example, each magnetic segment 120S can be attached to a rectangular substrate along the arrangement state to form an integrated structure. The substrate can be the same material as the resin sheet 15. In this case, the magnetic segments 120S can be arranged overlappingly, or they can be arranged in contact with each other, or they can be arranged with intervals between them.

[0165] like Fig. 10AAs shown, three long magnetic segments 120S are arranged in a row in the width direction. That is, the long sides 121 are arranged adjacent to each other. The three arranged magnetic segments 120S are cut along three cutting lines 24.

[0166] Two of the three cutting lines 24 are lines extending from the center of the short side 122 of the magnetic segment 120S arranged in the center in the width direction toward the long sides 121 of the outer sides of the magnetic segments 120S adjacent to both sides. The remaining one is an arc tangent to the other short sides 24 of the magnetic segment 120S arranged in the center, and is a line whose two ends intersect with the other two cutting lines 24. By cutting the magnetic segment 120S, a Fig. 10B A sector-shaped magnetic segment 120T is shown.

[0167] It should be noted that the magnetic sheet 110 may be composed of magnetic segments 120T of the same shape or of magnetic segments 120T of different shapes. For example, it may be composed of magnetic segments 120T having two shapes or of magnetic segments 120T having three or more shapes.

[0168] Fig.11 It is a top view explaining the structure of the magnetic sheet 110 having a circular shape. Fig.12 It is a description of the composition Fig.11 A top view of the shape of the magnetic segment 120T of the magnetic sheet 110.

[0169] In addition, the magnetic sheet 110 may have a polygonal shape as described above, or may have a Fig.11 As shown, it has a circular shape. Fig.12 As shown, the circular magnetic sheet 110 is formed by using a plurality of magnetic segments 120T having a fan-shaped shape in which the short sides 122 are bent into an arc shape.

[0170] exist Fig.11 In the embodiment, the central portion of the magnetic sheet 110 may be configured as a hole. In this case, the hole is smaller than the inner diameter of the coil.

[0171] Fig.13 It is a plan view for explaining another structure of the magnetic sheet 110 . Fig.14 It is a description of the composition Fig.13 A top view of the shape of the long strip-shaped magnetic segment 120S of the magnetic sheet.

[0172] Furthermore, the magnetic sheet 110 may be formed by using a plurality of magnetic segments 120T having a triangular shape as described above, or may be formed by using a plurality of magnetic segments 120T having a triangular shape as described above. Fig.13 and Fig.14 As shown, the magnetic structure is constructed using a plurality of magnetic segments 120Sc having a long strip shape.

[0173] Fig.13 , a magnetic sheet 110 formed using eight magnetic segments 120Sc having a long strip shape is shown. The eight magnetic segments 120Sc having a long strip shape are arranged radially.

[0174] like Fig.14 As shown, the magnetic segment 120Sc has two long sides 121c and two short sides 122. The length 121Lc of the long side 121c may be greater than Figure 3A The length 121L of the long side 121 in the illustrated magnetic segment 120S is long. Preferably, the length 121Lc is about twice as long as the length 121L.

[0175] By forming the magnetic sheet 110 using the long magnetic segments 120Sc, the number of steps in manufacturing the magnetic sheet 110 can be reduced compared to the case where the magnetic sheet 110 is formed using the triangular magnetic segments 120T.

[0176] exist Fig.13 In the embodiment, the central portion of the magnetic sheet 110 may be configured as a hole. In this case, the hole is smaller than the inner diameter of the coil.

[0177] Fig.15 This is a partially enlarged view illustrating the structure of the magnetic sheet 110 in which a plurality of magnetic segments 120T are stacked.

[0178] The magnetic sheet 110 may be composed of a single layer of magnetic segments 120T as described above, or may be composed of a plurality of layers of magnetic segments 120T. Fig.15 The example in which the magnetic sheet 110 is composed of two layers of magnetic segments 120T is shown. In other words, the example in which the first magnetic sheet 110 and the second magnetic sheet 110 are stacked is shown.

[0179] exist Fig.15 In FIG. 1 , the first magnetic sheet 110 and the second magnetic sheet 110 are stacked in a direction perpendicular to the paper surface. The first magnetic sheet 110 disposed on the back side of the paper surface is shown by a dotted line.

[0180] When viewed from the stacking direction, the first adjacent position 151 in the first magnetic sheet 110 and the second adjacent position 152 in the second magnetic sheet 110 are at different positions.

[0181] The first adjacent position 151 and the second adjacent position 152 are positions where adjacent magnetic segments 120T contact each other, for example, positions where the long sides 121 of adjacent magnetic segments 120T contact each other, positions where the oblique sides 123 contact each other, and positions where the long sides 121 contact the oblique sides 123 .

[0182] When configuring the magnetic sheet 110 in which a plurality of magnetic segments 120T are stacked, as described above, by stacking the magnetic segments 120T at offset positions, it is possible to suppress the continuous generation of magnetic gaps and improve the characteristics of the magnetic sheet.

[0183] Fig.16 The diagram is a diagram for explaining a method of forming a regular triangle-shaped magnetic segment 120T- 1 and a right-angled triangle-shaped magnetic segment 120T- 2 from a plurality of long strip-shaped magnetic segments 120S.

[0184] like Fig.16 As shown, a plurality of long strip-shaped magnetic segments 120S are arranged in the width direction and integrated. Fig.16 , a state where 24 to 25 magnetic segments 120S are integrated is shown.

[0185] The integrated magnetic segment 120S is cut along the cutoff line 24. The cutoff line 24 has a shape in which seven equilateral triangle-shaped magnetic segments 120T-1 and two right-angled triangle-shaped magnetic segments 120T-2 are formed from the integrated magnetic segment 120S.

[0186] The two right-angled triangle-shaped magnetic segments 120T- 2 are located at two ends of the integrated magnetic segment 120S, and the seven regular triangle-shaped magnetic segments 120T- 1 are located between the two right-angled triangle-shaped magnetic segments 120T- 2 .

[0187] Fig.17 It is a diagram for explaining the structure of the octagonal magnetic sheet 110 .

[0188] The seven regular triangle-shaped magnetic segments 120T-1 and the two right-angled triangle-shaped magnetic segments 120T-2 are formed as shown in FIG. Fig.17 As shown in FIG. 1 , the magnetic sheet 110 is formed by arranging the magnetic segments 120T-1 in an octagonal shape. In other words, the magnetic sheet 110 is formed by radially arranging seven equilateral triangle-shaped magnetic segments 120T-1 and two right-angled triangle-shaped magnetic segments 120T-2.

[0189] exist Fig.17 In the embodiment, the central portion of the magnetic sheet 110 may be configured as a hole. In this case, the hole is smaller than the inner diameter of the coil.

[0190] Fig.18 It is explained in Fig.17 FIG. 1 is a diagram showing a state in which a covering magnetic segment 120T-3 is arranged on the magnetic sheet 110.

[0191] like Fig.18 As shown, it can also be Fig.17The covering magnetic segment 120T-3 is arranged on the magnetic sheet 110. The covering magnetic segment 120T-3 is formed in a rectangular shape and attached to the magnetic sheet 110.

[0192] The position of the magnetic segment 120T-3 for attachment and covering is at least one of the positions where two equilateral triangle-shaped magnetic segments 120T-1 are adjacent, the position where an equilateral triangle-shaped magnetic segment 120T-1 and a right-angled triangle-shaped magnetic segment 120T-2 are adjacent, and the position where two right-angled triangle-shaped magnetic segments 120T-2 are adjacent. Fig.18 FIG. 2 shows a state where the covering magnetic segments 120T-3 are attached to all positions.

[0193] The adjacent positions are positions where magnetic gaps are likely to be formed. By attaching the covering magnetic segments 120T-3 to the adjacent positions, the influence of the magnetic gaps can be suppressed.

[0194] Next, refer to Figures 19 to 25 The method for manufacturing the magnetic sheet 110 will be described. First, the method for manufacturing the magnetic segment 120S constituting the magnetic sheet 110 and the magnetic segment 120T will be described.

[0195] Fig.19 1 is a schematic diagram for explaining a method for manufacturing the magnetic segment 120S.

[0196] The magnetic segment 120S is a magnetic segment constituting the magnetic segment 110 and the magnetic segment 120T. The magnetic segment 120S is used Fig.19 The manufacturing device 500 is shown in FIG. 1 . In the manufacturing device 500, a first unwinding roller 510, a first winding roller 520, a second unwinding roller 530, a laminating roller 540, a cracking roller 550, a flattening roller 560, and a third winding roller 570 are provided from upstream to downstream of the manufacturing process. A plurality of guide rollers 580 may be provided in the manufacturing device 500. In addition, the guide roller 580 may be arranged at a position not described as required.

[0197] Fig. 20 It is a cross-sectional view for explaining the structure of the stacked body supplied from the first unwinding roll 510 .

[0198] like Fig. 20 As shown, a laminated body in which a resin sheet 15 is laminated on the first surface 11A and the second surface 11B of the adhesive layer 10 is wound on the first unwinding roller 510. The resin sheet 15 arranged on the first surface 11A is a protective sheet, and the resin sheet 15 arranged on the second surface 11B is also recorded as a liner. The resin sheet 15 arranged on the first surface 11A is a sheet thinner than the resin sheet 15 arranged on the second surface 11B.

[0199] Fig.21This is a cross-sectional view for explaining the structure of a laminated body in which the resin sheet 15 is supplied from the first feeding roll 510 and peeled off.

[0200] The laminate unwound from the first unwinding roll 510 is as follows Fig.21 The resin sheet 15 disposed on the first surface 11A as shown is peeled off. Fig.19 As shown, the peeled resin sheet 15 is wound up by the first winding roller 520 .

[0201] Fig. 22 It is a cross-sectional view for explaining the structure of the magnetic ribbon 20 supplied from the second unwinding roller 530 .

[0202] The laminated body from which the resin sheet 15 disposed on the first surface 11A is peeled off is guided to the attaching roller 540 by the plurality of guide rollers 580. Furthermore, the magnetic thin ribbon 20 unwound from the second unwinding roller 530 is guided to the attaching roller 540. Fig. 22 As shown, the cracks 21 are not formed in the magnetic ribbon 20 guided to the attachment roller 540 .

[0203] Here, a method for manufacturing the magnetic thin ribbon 20 unwound from the second unwinding roller 530 is described. For example, the case where the magnetic thin ribbon 20 is a nanocrystalline alloy is described. The magnetic thin ribbon 20 is manufactured by a manufacturing method including the following steps: a step of rapidly cooling the alloy melt to obtain an amorphous alloy thin ribbon capable of nanocrystallization, and a heat treatment step of heat-treating the amorphous alloy thin ribbon at a temperature above the crystallization start temperature to form fine crystal grains.

[0204] The quenching is performed by a single roll method in which the molten metal is discharged onto a rotating cooling roll to be rapidly solidified. The magnetic ribbon 20 has a long strip shape with the longitudinal direction along the rotation direction of the cooling roll as the longitudinal direction. The length of the magnetic ribbon 20 in the longitudinal direction is, for example, 20,000 m.

[0205] The temperature of the heat treatment varies depending on the alloy composition, but is usually 450° C. or higher. The fine crystal grains are, for example, Fe of a body-centered cubic lattice structure in which Si etc. are dissolved. The fine crystal grains can be analyzed using X-ray diffraction and a transmission electron microscope.

[0206] In the nanocrystalline alloy, at least 50% by volume of the nanocrystalline alloy is occupied by fine grains with an average grain size of less than 100 nm as measured by the maximum size method. In addition, the portion other than the fine grains in the nanocrystalline alloy is mainly amorphous. The proportion of the fine grains can be substantially 100% by volume.

[0207] Fig.23 It is a cross-sectional view for explaining a state in which the magnetic thin ribbon 20 is bonded to the adhesive layer 10 by the bonding roller 540 .

[0208] like Fig.19As shown, the attaching roller 540 presses and adheres the magnetic thin ribbon 20 to the laminated body from which the resin sheet 15 has been peeled off. Specifically, the laminated body and the magnetic thin ribbon 20 are guided between two rollers arranged opposite to each other, and two rollers are used, such as Fig.23 As shown, the magnetic thin tape 20 is pressed and bonded to the first surface 11A of the adhesive layer 10 .

[0209] like Fig.19 As shown, the laminated body to which the magnetic thin ribbon 20 is bonded is guided from the attachment roller 540 to the crack roller 550 .

[0210] Fig.24 This is a cross-sectional view for explaining a state in which cracks 21 are formed in the magnetic ribbon 20 by the cracking roller 550 .

[0211] The crack roller 550 forms cracks 21 in the magnetic ribbon 20 bonded to the adhesive layer 10. Specifically, the laminated body bonded with the magnetic ribbon 20 is guided between two rollers arranged opposite to each other, and the roller with protrusions is pressed against the magnetic ribbon 20, as shown in FIG. Fig.24 As shown, cracks 21 are formed.

[0212] Of the two rollers, the roller without protrusions is disposed on the laminated body side from which the resin sheet 15 has been peeled. The magnetic ribbon 20 having the cracks 21 formed therein includes a plurality of small pieces 22. The plurality of small pieces 22 are bonded to the adhesive layer 10.

[0213] Here, the structure of the crack roller 550 is described. The crack roller 550 is a roller having a plurality of convex members arranged on the circumferential surface. The front end of the end of the convex member of the crack roller 550 can be flat, conical, inverted conical with a central depression, or cylindrical. The plurality of convex members can be arranged regularly or irregularly.

[0214] The long magnetic ribbon 20 is pressed against the crack roller 550, or the long magnetic ribbon 20 is passed between two crack rollers 550, thereby continuously forming cracks 21 on the magnetic ribbon 20. In addition, the convex member of the crack roller 550 is pressed against multiple locations on the surface of the magnetic ribbon 20, so that multiple cracks 21 are formed in the magnetic ribbon 20.

[0215] In the formation of cracks using the crack roller 550, it is preferable to further form cracks that connect multiple cracks 21 to each other in a mesh shape. Specifically, it is preferable to have a step of forming cracks that connect the multiple cracks 21 to each other in a mesh shape after pressing the crack roller 550 to the magnetic ribbon 20 to form multiple cracks 21.

[0216] For example, after the crack 21 is formed by directly applying an external force to the magnetic ribbon 20 using the crack roller 550, a second external force may be applied by bending or rolling up the magnetic ribbon 20 to form a crack that connects the plurality of cracks 21 to each other in a mesh shape. The crack that connects the cracks 21 to each other (the magnetic gap that connects the cracks to each other) is formed with the crack 21 as the starting point of brittle failure and / or cracking failure.

[0217] In the step of forming the cracks that connect the plurality of cracks 21 to each other in a mesh shape, the second external force described above may not be applied. In the case where the second external force is not applied, in the process of forming the plurality of cracks 21, the cracks that connect the plurality of cracks 21 to each other in a mesh shape are formed.

[0218] The laminate 100 guided from the cracking roller 550 to the flattening roller 560 is flattened by the flattening roller 560. It should be noted that the flattening roller 560 is also referred to as a reforming roller.

[0219] Specifically, the laminate is guided between two rollers disposed opposite to each other among the flattening rollers 560, and the laminate is sandwiched and pressed by the two rollers. Thus, the surface of the magnetic thin ribbon 20 having the cracks 21 formed therein is flattened.

[0220] The laminated body 100 after the flattening treatment is guided to the third winding roller 570 via the guide roller 580 . The laminated body 100 is wound up by the third winding roller 570 .

[0221] The laminate 100 is composed of one layer of the magnetic thin tape 20, the adhesive layer 10, and the resin sheet 15, and can be used as the magnetic segment 120S. In addition, the laminate can also be used to produce magnetic segments 120S of other structures.

[0222] Fig.25 It is a schematic diagram for explaining another example of a method for manufacturing the magnetic segment 120S.

[0223] Magnetic fragment 120S use Fig.25 The manufacturing device 600 shown is used for manufacturing. Fig.25 2 shows a manufacturing apparatus 600 for manufacturing a magnetic segment 120S including five layers of magnetic thin ribbons 20 .

[0224] In the manufacturing device 600, from the upstream to the downstream of the manufacturing process, there are provided a supply roller 601, a resin sheet winding roller 602, a first magnetic sheet unwinding roller 611, a first winding roller 612, a first attaching roller 613, a second magnetic sheet unwinding roller 621, a second winding roller 622, a second attaching roller 623, a third magnetic sheet unwinding roller 631, a third winding roller 632, a third attaching roller 633, a fourth magnetic sheet unwinding roller 641, a fourth winding roller 642, a fourth attaching roller 643, a fifth magnetic sheet unwinding roller 651, a fifth attaching roller 653, a flattening roller 663, and a laminated substrate winding roller 670. A plurality of guide rollers 680 may also be provided in the manufacturing device 600. It should be noted that the guide roller 680 may also be arranged at a position not described as required.

[0225] It should be noted that the manufacturing device 600 can also manufacture a magnetic segment 120S in which the number of magnetic thin ribbons 20 is more than 2 layers and less than 20 layers. In this case, the number of the first magnetic sheet unwinding rollers 611 and the like is changed according to the number of magnetic thin ribbons 20. In addition, the magnetic thin ribbon unwinding from the unwinding rollers 611 and the like can also be a multi-layer magnetic thin ribbon. It should be noted that the number of layers of the magnetic thin ribbons 20 of the manufactured magnetic segment 120S can be appropriately determined.

[0226] However, when the magnetic segment 120S is rolled up, if the number of layers of the magnetic ribbon 20 is large, it may be difficult to roll up, or a shape defect may occur during rolling up. Therefore, when the magnetic segment 120S is rolled up, the number of layers is preferably 15 layers or less. More preferably, it is 10 layers or less. In addition, the number of layers of the magnetic ribbon 20 is preferably 2 layers or more, preferably 3 layers or more, and preferably 4 layers or more. In addition, the magnetic segment 120S with more than 20 layers may be produced, but since the device becomes too large, it is preferably 20 layers or less.

[0227] like Fig. 20 As shown, a laminated body in which the resin sheet 15 is laminated on the first surface 11A and the second surface 11B of the adhesive layer 10 is wound around a supply roll 601 .

[0228] The laminated body unwound from the supply roll 601 is as follows Fig.21 The resin sheet 15 disposed on the first surface 11A as shown in FIG. Fig.25 The sheet is wound up on the resin sheet winding roll 602 as shown.

[0229] The laminated body from which the resin sheet 15 disposed on the first surface 11A is peeled off is guided to the first attaching roller 613 by the guide roller 680. Furthermore, the laminated body 100 ( Fig.19 The laminated body 100 produced in the process is guided to the first attaching roller 613.

[0230] The first attaching roller 613 presses and bonds the other laminate 100 to the laminate from which the resin sheet 15 has been peeled. Specifically, the laminate and the other laminate 100 are guided between two rollers disposed opposite to each other, and the magnetic tape 20 of the other laminate 100 is pressed and bonded to the first surface 11A of the adhesive layer 10 using the two rollers.

[0231] The resin sheet 15 of the laminate 100 bonded by the first attaching roller 613 is peeled off from the laminate and wound up on the first winding roller 612. The laminate after the resin sheet 15 is wound up on the first winding roller 612 is guided to the second attaching roller 623. Furthermore, the laminate 100 unwound from the second magnetic sheet unwinding roller 621 is guided to the second attaching roller 623.

[0232] The second attaching roller 623 presses and bonds the other laminate 100 to the laminate guided from the first attaching roller 613. Here, the magnetic ribbon 20 of the other laminate 100 is pressed and bonded to the laminate guided from the first attaching roller 613.

[0233] The resin sheet 15 of the laminated body 100 bonded by the second attaching roller 623 is peeled off from the laminated body and is wound up by the second winding roller 622 .

[0234] The laminated body after the resin sheet 15 is wound up by the second winding roller 622 is guided to the third attaching roller 633. Furthermore, the laminated body 100 unwound from the third magnetic sheet unwinding roller 631 is guided to the third attaching roller 633.

[0235] The third attaching roller 633 presses and bonds the other laminate 100 to the laminate guided from the second attaching roller 623. Here, the magnetic ribbon 20 of the other laminate 100 is pressed and bonded to the laminate guided from the second attaching roller 623.

[0236] The resin sheet 15 of the laminated body 100 bonded by the third attaching roll 633 is peeled off from the laminated body and is wound up by the third winding roll 632 .

[0237] The laminated body after the resin sheet 15 is wound up by the third winding roller 632 is guided to the fourth attaching roller 643. Furthermore, the laminated body 100 unwound from the fourth magnetic sheet unwinding roller 641 is guided to the fourth attaching roller 643.

[0238] The fourth attaching roller 643 presses and bonds the other laminate 100 to the laminate guided from the third attaching roller 633. Here, the magnetic ribbon 20 of the other laminate 100 is pressed and bonded to the laminate guided from the third attaching roller 633.

[0239] The resin sheet 15 of the laminated body 100 bonded by the fourth attaching roll 643 is peeled off from the laminated body and is wound up by the fourth winding roll 642 .

[0240] The laminated body after the resin sheet 15 is wound up by the fourth winding roller 642 is guided to the fifth attaching roller 653. Furthermore, the laminated body 100 unwound from the fifth magnetic sheet unwinding roller 651 is guided to the fifth attaching roller 653.

[0241] The fifth attaching roller 653 presses and bonds the other laminate 100 to the laminate guided from the fourth attaching roller 643. Here, the magnetic ribbon 20 of the other laminate 100 is pressed and bonded to the laminate guided from the fourth attaching roller 643.

[0242] The laminated body guided from the fifth attaching roller 653 to the flattening roller 663 is flattened by the flattening roller 663 .

[0243] The laminated body after the flattening treatment is guided to the laminated base winding roller 670 via the guide roller 680 . The laminated body 300 is wound up on the laminated base winding roller 670 .

[0244] It should be noted that, in addition to the method of winding up the laminated body 300 on the laminated base winding roll 670, the laminated body 300 may be continuously cut into a desired length.

[0245] The laminated body 300 manufactured by the manufacturing apparatus 600 is as follows: Figure 3A As shown in FIG. 1 , the long side 121 is cut into a length 121L to form a long strip-shaped magnetic segment 120S. The long strip-shaped magnetic segment 120S is cut along the cutting line 24 to form a long strip-shaped magnetic segment 120S. Figure 3B Two triangular shaped magnetic segments 120T are shown.

[0246] Alternatively, the stacked bodies 300 may be arranged and integrated and then processed into Figure 2B , Figure 3B For example, as shown in Figure 10, Fig.16 As shown, the laminated body 300 can be used as the magnetic segment 120S. In addition, the laminated body 300 can be further laminated to be used as the magnetic segment 120S.

[0247] Next, refer to Figure 1 The characteristics of the magnetic sheet 110 having the above-mentioned structure will be described.

[0248] If current flows in the coil 200, magnetic flux is formed around the coil 200. The magnetic flux flows along the center of the coil 200 along the same direction as the coil 200. Figure 1 For example, it flows from the coil 200 toward the magnetic sheet 110 .

[0249] The magnetic flux penetrating the center of the coil 200 flows inside the magnetic sheet 110 toward the outer periphery of the coil 200. In other words, the magnetic flux flows radially inside the magnetic sheet 110 from the center of the coil 200 toward the outer periphery.

[0250] The magnetic sheet 110 that forms the magnetic circuit is radially arranged with a plurality of magnetic segments 120T. That is, the plurality of magnetic segments 120T are arranged in a radial arrangement in the casting direction. In other words, the plurality of magnetic segments 120T are arranged in a casting direction that is consistent with the direction of the magnetic flux in the magnetic sheet 110 generated by the current flowing in the winding coil 200. More preferably, the plurality of magnetic segments 120T are arranged in a casting direction that is parallel to the direction of the magnetic flux in the magnetic sheet 110. Here, the casting direction is the same direction as the direction of anisotropy.

[0251] By arranging a plurality of magnetic segments 120T in a radial arrangement in the casting direction, the Q2 value of the magnetic sheet 110 increases from the center to the periphery of the coil 200. That is, the electromagnetic shielding effect brought about by the nanocrystalline alloy thin strip constituting the magnetic sheet 110 is easily exerted, and for the surrounding coil 200, it is also easy to suppress the reduction of the electromagnetic shielding characteristics of the magnetic sheet 110.

[0252] Next, refer to Figures 26 to 34 The evaluation of the characteristics of the magnetic sheet 110 having the above-mentioned structure will be described. Examples 1 to 4 and Comparative Example 1 were used for the evaluation.

[0253] Fig.26 It is a diagram for explaining the structure of the magnetic sheet 110 of Example 1. Fig. 27 It is a diagram for explaining the structure of the magnetic sheet 110 of the second embodiment. Fig.28 It is a diagram for explaining the structure of the magnetic sheet 110 of Example 3. Fig.29 It is a diagram for explaining the structure of the magnetic sheet 110 of the fourth embodiment. Fig.30 It is a diagram for explaining the structure of the magnetic sheet 111 of Comparative Example 1.

[0254] like Fig.26 As shown, the magnetic sheet 110 of Example 1 is a sheet formed by arranging 14 triangular magnetic segments 120T in a radial pattern. The magnetic sheet 110 of Example 1 has a heptagonal shape. In addition, the magnetic sheet 110 of Example 1 has a heptagonal shape inscribed in a circle with a diameter of 60 mm.

[0255] like Fig. 27 As shown, the magnetic sheet 110 of Example 2 is a sheet formed by arranging 16 fan-shaped magnetic segments 120T in a radial pattern. The magnetic sheet 110 of Example 2 has a circular shape with a diameter of 60 mm.

[0256] like Fig.28 As shown, the magnetic sheet 110 of Example 3 is a sheet formed by arranging 16 triangular magnetic segments 120T in a radial pattern. The magnetic sheet 110 of Example 3 has an octagonal shape. In addition, the magnetic sheet 110 of Example 3 has an octagonal shape inscribed in a circle with a diameter of 60 mm.

[0257] like Fig.29 As shown, the magnetic sheet 110 of Example 4 is a sheet composed of six long magnetic segments 120S arranged radially. The length of the magnetic segments 120S constituting the magnetic sheet 110 of Example 4 is 60 mm in the longitudinal direction and 10 mm in the width direction.

[0258] like Fig.30 As shown, the magnetic sheet 111 of Comparative Example 1 is a sheet composed of six long magnetic segments 120S arranged in parallel. The length of the magnetic segment 120S constituting the magnetic sheet 111 of Comparative Example 1 is 60 mm in the longitudinal direction and 10 mm in the width direction.

[0259] Next, refer to Fig.31 Next, the measuring device 300 used for the evaluation will be described. Fig.31 It is a figure explaining the measuring device 300 for evaluating a magnetic sheet.

[0260] The measuring device 300 is provided with an LCR measuring instrument 310, a measuring coil 320, and an aluminum plate 330. The LCR measuring instrument 310 is connected to the measuring coil 320 and is a device for measuring Ls (inductance (H)) and Rs (resistance (Ω)) in the magnetic sheet 110 together with the measuring coil 320. The LCR measuring instrument 310 is E4980A from Keysight.

[0261] The measuring coil 320 is a coil disposed with the aluminum plate 330 sandwiching the magnetic sheet 110. The diameter of the measuring coil is 50 mm. The Ls of the measuring coil 320 at a frequency of 85 kHz is 3.5 μH, and the Rs is 28 mΩ.

[0262] The aluminum plate 330 is a plate member formed in a rectangular shape. Specifically, it is a plate-like member having a square shape with one side being 60 mm and a thickness of 2 mm.

[0263] Furthermore, Q1 is calculated based on Ls and Rs measured by the measuring device 300. The calculation formula of Q1=Ls / Rs×2πf is used in the calculation. Here, f is a frequency (Hz).

[0264] Next, refer to Figure 32 to Figure 34 The measurement results of the measurement device 300 will be described. Fig.32It is a graph showing the value of Q1 calculated based on the measurement results. Fig.33 It is a graph showing the measured value of Ls. Fig.34 It is a graph showing the measured Rs value.

[0265] exist Figure 32 to Figure 34 In the figure, the graph E1 represented by the hollow circle is a graph showing the calculation results of the magnetic sheet 110 of Example 1. The graph E2 represented by the hollow quadrilateral is a graph showing the calculation results of the magnetic sheet 110 of Example 2. The graph E3 represented by the hollow rhombus is a graph showing the calculation results of the magnetic sheet 110 of Example 3. The graph E4 represented by the hollow triangle is a graph showing the calculation results of the magnetic sheet 110 of Example 4. The graph C1 represented by the black circle is a graph showing the calculation results of the magnetic sheet 111 of Comparative Example 1.

[0266] Fig.32 The horizontal axis in represents the frequency (kHz) used for measurement, and the vertical axis represents the value of Q1. Fig.33 The horizontal axis in represents the frequency (kHz) used for measurement, and the vertical axis represents the value of Ls (H). Fig.34 The horizontal axis in φ represents the frequency (kHz) used for measurement, and the vertical axis represents the value of Rs (Ω).

[0267] like Fig.32 As shown, the value of Q1 reaches a peak at a frequency of about 110 kHz as a whole, and decreases as the frequency moves away from 110 kHz. The graph E1 of the magnetic sheet 110 of Example 1, the graph E2 of the magnetic sheet 110 of Example 2, the graph E3 of the magnetic sheet 110 of Example 3, and the graph E4 of the magnetic sheet 110 of Example 4 are located above the graph C1 of the magnetic sheet 111 of Comparative Example 1 at all frequencies.

[0268] In other words, the magnetic sheet 110 of Example 1, the magnetic sheet 110 of Example 2, the magnetic sheet 110 of Example 3, and the magnetic sheet 110 of Example 4 have a Q1 value greater than that of the magnetic sheet 111 of Comparative Example 1 at all frequencies.

[0269] In addition, the magnetic sheets 110 of Examples 3 and 110 of Examples 4 have larger values ​​of Q1 at all frequencies than the magnetic sheets 110 of Examples 1 and 2.

[0270] The magnetic sheet 110 of Example 1 has a smaller Q1 value than the magnetic sheet 110 of Example 2 in a frequency region below about 100 kHz, and has a larger Q value than the magnetic sheet 110 of Example 2 in a frequency region above about 100 kHz. The magnetic sheet 110 of Example 3 has a smaller Q1 value than the magnetic sheet 110 of Example 4 in a frequency region below about 110 kHz, and has a larger Q value than the magnetic sheet 110 of Example 4 in a frequency region above about 110 kHz.

[0271] It should be noted that the operating frequency used in the non-contact charging circuit for automobiles is about 85kHz, and the operating frequency used in the non-contact charging circuit for smartphones is about 128kHz and 360kHz. That is, it is shown that the magnetic sheet 110 of Example 1, the magnetic sheet 110 of Example 2, the magnetic sheet 110 of Example 3, and the magnetic sheet 110 of Example 4 have a higher value of Q1 at the operating frequency used in the non-contact charging circuit for automobiles and the non-contact charging circuit for smartphones.

[0272] like Fig.33 As shown, the value of Ls decreases as the frequency increases. In the low frequency region, the Ls value decreases more greatly as the frequency increases than in the high frequency region.

[0273] The graph E1 of the magnetic sheet 110 of Example 1, the graph E2 of the magnetic sheet 110 of Example 2, the graph E3 of the magnetic sheet 110 of Example 3, and the graph E4 of the magnetic sheet 110 of Example 4 are located above the graph C1 of the magnetic sheet 111 of Comparative Example 1 at all frequencies. In other words, the magnetic sheet 110 of Example 1, the magnetic sheet 110 of Example 2, the magnetic sheet 110 of Example 3, and the magnetic sheet 110 of Example 4 have Ls values ​​greater than the magnetic sheet 111 of Comparative Example 1 at all frequencies.

[0274] The value of Ls of the magnetic sheet 110 of Example 3 is the largest. The value of Ls of the magnetic sheet 110 of Example 1 is the second largest. The value of Ls of the magnetic sheet 110 of Example 2 is the third largest. The value of Ls of the magnetic sheet 110 of Example 4 is the fourth largest.

[0275] like Fig.34 As shown in FIG. 1 , the value of Rs increases as the frequency increases. In a high frequency region, the value of Rs increases more greatly as the frequency increases than in a low frequency region.

[0276] The graph E1 of the magnetic sheet 110 of Example 1, the graph E2 of the magnetic sheet 110 of Example 2, the graph E3 of the magnetic sheet 110 of Example 3, and the graph E4 of the magnetic sheet 110 of Example 4 are located below the graph C1 of the magnetic sheet 111 of Comparative Example 1 at all frequencies. In other words, the values ​​of Rs of the magnetic sheet 110 of Example 1, the magnetic sheet 110 of Example 2, the magnetic sheet 110 of Example 3, and the magnetic sheet 110 of Example 4 are smaller than those of the magnetic sheet 111 of Comparative Example 1 at all frequencies.

[0277] The Rs value of the magnetic sheet 110 of Example 4 is the smallest. The Rs value of the magnetic sheet 110 of Example 3 is the second smallest. The Rs value of the magnetic sheet 110 of Example 2 is the third smallest. The Rs value of the magnetic sheet 110 of Example 1 is the fourth smallest.

[0278] According to the magnetic sheet 110 of the above structure, it is easy to make the direction of the magnetic flux of the magnetic sheet 110 generated by the current flowing through the encircling coil 200 used in combination with the magnetic sheet 110 coincide with the direction of the anisotropy of the magnetic sheet 110. Specifically, it is easy to make the direction of the anisotropy in the magnetic segment 120T, in other words, the direction of the low direct current relative magnetic permeability μr, that is, the direction of the high Q2 value, and the direction of the magnetic flux of the magnetic sheet 110 generated by the current flowing through the encircling coil 200 coincide. Therefore, even if used with respect to the encircling coil 200, it is easy to suppress the reduction of the magnetic shielding characteristics of the magnetic sheet 110. In addition, it is easy to improve the characteristics of the coil 200.

[0279] In this case, the direction of anisotropy can be treated as the direction of anisotropy of the magnetic ribbon 20 constituting the magnetic sheet 110. When a nanocrystalline alloy ribbon is used as the magnetic ribbon 20, the direction of anisotropy is the direction of the nanocrystalline alloy ribbon.

[0280] Regarding the direction of anisotropy, the values ​​of the direct current relative magnetic permeability μr are different in a first direction in the plane direction of the magnetic thin strip 20 and in a second direction orthogonal thereto, and the direction with a lower value of the direct current relative magnetic permeability μr in the first direction and the second direction is set as the direction of anisotropy. For example, the casting direction can be evaluated as the first direction.

[0281] Here, the difference between the value of the DC relative magnetic permeability μ in the first direction and the value of the DC relative magnetic permeability μr in the second direction is preferably 3% or more as calculated by the following formula, and more preferably 10% or more.

[0282] (larger μr value - smaller μr value) / larger μr value × 100 (%)

[0283] By setting the shape of the magnetic segment 120T to a shape such as a triangle whose dimension in the width direction increases from one end side to the other end side, it is easy to suppress the change in the dimension of the magnetic sheet 110 in the stacking direction. That is, the one end side with a relatively small dimension in the width direction is arranged at the center, and the other end side with a relatively large dimension in the width direction is arranged at the periphery. When multiple magnetic segments 120T are arranged radially, it is easy to suppress the overlap of multiple magnetic segments 120T at the radial center. By suppressing overlap, the dimension of the magnetic sheet 110 in the stacking direction at the radial center is not easy to increase, and the difference in the dimension in the stacking direction with the peripheral side is easy to become smaller.

[0284] By stacking the magnetic thin ribbons 20 via the adhesive layer 10, it is easy to stack a plurality of magnetic thin ribbons 20. The adhesive layer 10 is disposed between the stacked and adjacent magnetic thin ribbons 20. The adhesive layer 10 adheres to the magnetic thin ribbons 20 and can hold the magnetic thin ribbons 20. By stacking the magnetic thin ribbons 20 with the adhesive layer 10 sandwiched therebetween, it is easy to hold the relative positions of the plurality of magnetic thin ribbons 20 and to stack them easily.

[0285] By making the magnetic thin strip 20 a nanocrystalline alloy thin strip, the magnetic thin strip 20 can be made into a soft magnetic thin strip. In addition, the magnetic thin strip can be formed using an alloy. Compared with other magnetic materials, the nanocrystalline alloy thin strip is thin and easy to obtain high properties. Therefore, it is beneficial to make the magnetic sheet 110 high-performance and thin.

[0286] By using the magnetic thin ribbon 20 manufactured by the single roll method, it is easy to form the magnetic thin ribbon 20 in a long strip shape. In addition, it is easy to form the magnetic thin ribbon 20 in which the casting direction is the anisotropic direction.

[0287] By stacking a plurality of magnetic thin strips to form the magnetic sheet 110, the magnetic shielding property of the magnetic sheet 110 is less likely to be reduced. That is, by stacking the magnetic thin strips 20, the magnetic property of the magnetic sheet 110 can be improved, and a magnetic sheet 110 with higher properties can be formed.

[0288] When viewed from the stacking direction, the first adjacent position 151 and the second adjacent position 152 are at different positions, and thus when viewed from the stacking direction, the magnetic segment 120T in the second magnetic sheet 110 is arranged at the first adjacent position 151. In addition, the magnetic segment 120T in the first magnetic sheet 110 is arranged at the second adjacent position 152. As a result, it is possible to suppress the continuous formation of magnetic gaps in the stacking direction, and the characteristics of the magnetic shield in the magnetic sheet 110 are not easily reduced.

[0289] It should be noted that the technical scope of the present disclosure is not limited to the above-mentioned embodiments, and various changes can be made within the scope of the main purpose of the present disclosure. For example, the present disclosure is not limited to being applied to the above-mentioned embodiments, but can also be applied to embodiments formed by appropriately combining these embodiments, without special limitation.

Claims

1. A sheet-like magnetic component having a plurality of magnetic segments, The magnetic segment is formed in a long strip shape and has anisotropy that magnetic properties in a length direction are different from magnetic properties in a width direction intersecting the length direction. The plurality of magnetic segments are arranged radially.

2. The sheet-like magnetic member according to claim 1, wherein: The magnetic segment has a shape in which the dimension in the width direction increases from one end side toward the other end side in the length direction. The plurality of magnetic segments are arranged in a radial pattern with the one end side facing the center side and the other end side facing the outer peripheral side.

3. The sheet-like magnetic member according to claim 1, wherein: The magnetic segment comprises a plurality of magnetic thin strips and a plurality of adhesive layers. The magnetic thin tape is stacked in a plurality of layers via the adhesive layer.

4. The sheet-like magnetic member according to claim 3, wherein: The magnetic thin ribbon is a nanocrystalline alloy thin ribbon.

5. The sheet-like magnetic member according to claim 3 or 4, wherein: The magnetic thin ribbon is a member produced by a single roll method in which a molten metal is discharged onto a rotating cooling roll and rapidly solidified. When the direction of the magnetic thin strip along the rotation direction of the cooling roll is defined as a casting direction, a direction from one end side toward the other end side is a direction along the casting direction. 6 . The sheet-like magnetic member according to claim 1 , which is formed by laminating a plurality of magnetic sheets in which a plurality of the magnetic segments are radially arranged.

7. The sheet-like magnetic member according to claim 1, comprising: a first magnetic sheet formed by arranging a plurality of the magnetic segments in a radial manner, and A second magnetic sheet formed by a plurality of the magnetic segments being arranged radially and stacked adjacent to the first magnetic sheet; When viewed in the stacking direction, a first adjacent position where the plurality of magnetic segments in the first magnetic sheet are adjacent to each other is different from a second adjacent position where the plurality of magnetic segments in the second magnetic sheet are adjacent to each other.

8. A sheet-like magnetic member, which is formed by arranging a plurality of magnetic thin strips so as to have an area larger than the area of ​​each of the magnetic thin strips, The magnetic thin strip has different values ​​of direct current relative magnetic permeability μr in a first direction in the plane direction and in a second direction orthogonal thereto, and in the first direction and the second direction, the direction with a lower value of direct current relative magnetic permeability μr is taken as the direction of anisotropy. Each of the magnetic thin strips is configured such that when the sheet-like magnetic member is configured near a coil formed in a ring shape, a magnetic flux is generated in the sheet-like magnetic member due to the relationship with the current flowing in the coil, and the direction of the magnetic flux and the direction of the anisotropy are within 60°.

9. The sheet-like magnetic member according to claim 8, wherein: The magnetic thin tape is stacked in multiple layers.

10. The sheet-like magnetic member according to claim 8 or 9, wherein: The magnetic thin strip is a nanocrystalline alloy thin strip, and the anisotropy direction is the casting direction of the nanocrystalline alloy thin strip.

11. A sheet-like magnetic member, which is formed by arranging a plurality of magnetic thin strips so as to have an area larger than the area of ​​each of the magnetic thin strips, The magnetic thin strip has different values ​​of direct current relative magnetic permeability μr in a first direction in the plane direction and in a second direction orthogonal thereto, and in the first direction and the second direction, the direction with a lower value of direct current relative magnetic permeability μr is taken as the direction of anisotropy. The sheet-like magnetic member is arranged near the coil formed in a surrounding shape. Each magnetic thin strip is arranged opposite to the coil, In each magnetic thin strip, the direction of the anisotropy of the magnetic thin strip and the direction of the current of the coil in the portion facing the magnetic thin strip are in an intersecting relationship, and the angle of the intersection is 30° or more.

12. The sheet-like magnetic member according to claim 11, wherein: The magnetic thin tape is stacked in multiple layers.

13. The sheet-like magnetic member according to claim 11 or 12, wherein: The magnetic thin strip is a nanocrystalline alloy thin strip, and the anisotropy direction is the casting direction of the nanocrystalline alloy thin strip.

14. A sheet-like magnetic member, which is formed by arranging a plurality of magnetic thin strips so as to have an area larger than the area of ​​each of the magnetic thin strips, The magnetic thin strip has different values ​​of direct current relative magnetic permeability μr in a first direction in the plane direction and in a second direction orthogonal thereto, and in the first direction and the second direction, the direction with a lower value of direct current relative magnetic permeability μr is taken as the direction of anisotropy. The sheet-like magnetic member is arranged near the coil formed in a surrounding shape. Each magnetic thin strip is arranged opposite to the coil, In each magnetic thin strip, an angle formed by a direction of anisotropy of the magnetic thin strip and a normal line of the coil in a portion facing the magnetic thin strip is 60° or less.

15. The sheet-like magnetic member according to claim 14, wherein: The magnetic thin tape is stacked in multiple layers.

16. The sheet-like magnetic member according to claim 14 or 15, wherein: The magnetic thin strip is a nanocrystalline alloy thin strip, and the anisotropy direction is the casting direction of the nanocrystalline alloy thin strip.

Images