Manufacturing method for sheet-shaped magnetic member

Abstract

To provide a cracking roll that allows easy structural changes even if the crack morphology changes, and to provide a manufacturing method for a sheet-shaped magnetic member using the cracking roll.SOLUTION: The manufacturing method for a sheet-shaped magnetic member includes forming an adhesive layer on a first surface of a nanocrystalline alloy thin strip, applying a cracking roll directly to a second surface of the nanocrystalline alloy thin strip that is opposite the first surface of the nanocrystalline alloy thin strip to form cracks in the nanocrystalline alloy thin strip, fabricating the nanocrystalline alloy thin strip with cracks, and stacking the multiple nanocrystalline alloy thin strips with the cracks through the adhesive layer to manufacture a sheet-shaped magnetic member with multiple nanocrystalline alloy thin strips stacked. The cracking roll includes a plurality of ring-shaped members including a plurality of protrusions on the outer peripheral surface. The plurality of ring-shaped members is arranged in the axial direction.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a method for manufacturing a sheet-shaped magnetic member used for magnetic cores, inductors, magnetic shields, and the like. [Background technology]

[0002] In recent years, non-contact charging, which uses transmission coils on both the power supply side and the power receiving side to transmit power using electromagnetic induction, has been attracting attention. In non-contact charging, magnetic flux generated in the primary transmission coil of the power supply device generates an electromotive force in the secondary transmission coil of the power receiving device through the housings of the power supply device and the power receiving device, thereby supplying power.

[0003] Non-contact charging is becoming popular for electronic devices such as tablet information terminals, music players, smartphones, and mobile phones. Non-contact charging is also applicable to electronic devices other than those mentioned above, electric vehicles, and drones. It is also applicable to transport vehicles such as forklifts and AGVs (Automated Guided Vehicles), railways, streetcars, and the like.

[0004] In non-contact charging, a magnetic sheet may be combined with the above-mentioned transmission coil (power supply side and power receiving side). This magnetic sheet is mainly used to improve the transmission efficiency of non-contact charging and to prevent leakage of magnetic flux from the non-contact charging circuit to other circuits (magnetic shield). Various methods have been proposed as a method for manufacturing the above-mentioned magnetic sheet (see, for example, Patent Documents 1 to 3). Patent Documents 1 to 3 disclose manufacturing methods including a step of dividing a thin plate-shaped magnetic material contained in a magnetic sheet or a ribbon of an amorphous alloy or nanocrystalline alloy (hereinafter also referred to as an "alloy thin ribbon") into a plurality of pieces for the purpose of improving the Q value or reducing eddy current loss.

[0005] Patent Document 1 discloses a manufacturing method including a step of forming a magnetic sheet by adhering an alloy ribbon to an adhesive layer provided on a sheet substrate, and a step of dividing the alloy ribbon into several pieces by an external force while maintaining the alloy ribbon adhered to the sheet substrate.

[0006] Patent Document 2 discloses a method for producing a magnetic sheet in which an alloy ribbon is heat-treated and then flaked to separate the alloy ribbon into a large number of small pieces or to form cracks in the alloy ribbon. The magnetic sheet has a configuration in which a plurality of alloy ribbons are laminated and adhesive layers or double-sided tape are disposed between the plurality of alloy ribbons. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] JP 2008-112830 A [Patent Document 2] Special Publication No. 2015-505166 [Patent Document 3] International Publication No. 2020-235642 Summary of the Invention [Problem to be solved by the invention]

[0008] Nanocrystalline alloy ribbons are used as one of the magnetic materials used in magnetic sheets. Then, cracks may be formed in the nanocrystalline alloy ribbons and the nanocrystalline alloy ribbons may be processed into small pieces. At this time, it is described in prior art documents that a cracking roll is pressed against the nanocrystalline alloy ribbon to form cracks in the nanocrystalline alloy ribbon. Nanocrystalline alloy ribbons have a brittle nature compared to amorphous alloy ribbons, and are more susceptible to cracks.

[0009] Although it is easy to form cracks in nanocrystalline alloy ribbons, the cracks tend to vary in shape, making it difficult to form cracks of a uniform shape. In addition, when used as a magnetic sheet, the optimal size of the pieces may differ depending on the application. Therefore, various studies have been conducted on the formation of cracks, but the optimal form of cracks and the method for producing them have not been determined.

[0010] The cracking roll described above has protrusions on its surface. The shape and arrangement of the protrusions are designed to produce optimal pieces depending on the application. In other words, the shape of the protrusions of the cracking roll is designed for each optimal crack shape of the nanocrystalline alloy ribbon. However, it is not easy to form protrusions on the entire outer peripheral surface of a cylindrical (columnar) cracking roll, and it is also not easy to prepare a cracking roll for each design change.

[0011] The present disclosure provides a cracking roll whose structure can be easily changed even if a change occurs in the form of cracks, and provides a method for manufacturing a sheet-shaped magnetic member using the cracking roll. [Means for solving the problem]

[0012] The present disclosure provides a method for producing a nanocrystalline alloy ribbon having a crack formed therein, comprising: forming an adhesive layer on a first surface of a nanocrystalline alloy ribbon; directly applying a cracking roll to a second surface of the nanocrystalline alloy ribbon opposite to the first surface, thereby forming cracks in the nanocrystalline alloy ribbon; A method for producing a sheet-like magnetic member, comprising stacking a plurality of nanocrystalline alloy ribbons having the cracks formed therein via the adhesive layer to produce a sheet-like magnetic member in which a plurality of nanocrystalline alloy ribbons are stacked, In this method for manufacturing a sheet-shaped magnetic member, the cracking roll comprises a plurality of ring-shaped members each having a plurality of protrusions on its outer circumferential surface, and the plurality of ring-shaped members are arranged in line in the axial direction. Effect of the Invention

[0013] According to the present disclosure, it is possible to provide a cracking roll whose structure can be easily changed in response to changes in the crack shape. In addition, it is possible to produce nanocrystalline alloy ribbons having a desired crack shape by using the cracking roll. In addition, it is possible to provide a sheet-shaped magnetic member by stacking the nanocrystalline alloy ribbons. [Brief description of the drawings]

[0014] [Figure 1] 1A and 1B are a front view and a side view, respectively, of a ring-shaped member having a plurality of protrusions on its outer circumferential surface according to the present disclosure. [Diagram 2] FIG. 2 is a side view of an example of a cracking roll of the present disclosure. [Diagram 3] 4 is a conceptual diagram of an example of a protrusion of a ring-shaped member according to the present disclosure. FIG. [Figure 4] 13 is a conceptual diagram of another example of a protrusion of a ring-shaped member according to the present disclosure. FIG. [Diagram 5] 1A and 1B are cross-sectional views of the vicinity of the tip of a protrusion of a ring-shaped member according to the present disclosure, where (a) is a first example and (b) is a second example. [Figure 6] 1 is an observation photograph of cracks formed in the nanocrystalline alloy ribbon of the present disclosure. [Figure 7] FIG. 7 is a replica of the crack lines in the photograph of FIG. 6. [Figure 8] FIG. 13 is a diagram showing the length of the pieces. [Figure 9] FIG. 2 is a diagram showing the state in which the tips of the protrusions of a cracking roll come into contact with the nanocrystalline alloy ribbon of the present disclosure. [Figure 10] FIG. 2 is a cross-sectional view of an example in which an adhesive layer is disposed on one surface of a nanocrystalline alloy ribbon having cracks formed therein according to the present disclosure. [Figure 11] FIG. 2 is a schematic diagram of an example of a manufacturing method for forming cracks in the nanocrystalline alloy ribbon of the present disclosure. [Figure 12] FIG. 2 is a schematic diagram of a laminate used in an example of a manufacturing method for forming cracks in a nanocrystalline alloy ribbon according to the present disclosure. [Figure 13] 1A to 1C are schematic diagrams illustrating an example of a method for producing a sheet-shaped magnetic member in which nanocrystalline alloy ribbons according to the present disclosure are stacked. [Figure 14] 1 is a schematic diagram of an example of a sheet-shaped magnetic member according to the present disclosure. [Figure 15] FIG. 2 is a schematic side view of a sheet-shaped magnetic member (25 layers) according to the present disclosure. [Figure 16] 13 is a graph showing the value of Q calculated based on the measurement results. [Figure 17] 1 is a graph showing measured Ls values. [Figure 18] 1 is a graph showing measured Rs values. [Figure 19] FIG. 2 is a diagram illustrating a measuring device used in the evaluation of the present embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The embodiments of the present disclosure will be described below with reference to the drawings. Note that the drawings are merely examples, and the dimensional ratios in the drawings do not necessarily represent the actual dimensional ratios. In addition, the present disclosure is not limited to those shown in the drawings, and can be modified as appropriate.

[0016] The cracking roll of the present disclosure will be described with reference to Figs. 1 to 5. Fig. 1 is a front view (a) and a side view (b) of a ring-shaped member used in the cracking roll of the present disclosure. The ring-shaped member 1 of the present disclosure has a plurality of protrusions 2 on its outer peripheral surface. As shown in Fig. 3, the protrusions 2 have a triangular shape 5 extending in the axial direction of the ring-shaped member. Here, the protrusions 2 are formed from one end face to the other end face in the thickness direction of the ring-shaped member 1. The protrusions 2 have a linear tip extending in the axial direction of the ring-shaped member 1. The linear tip may be an arc-shaped tip, a flat tip, or a linear tip having a width.

[0017] The protrusion 2 of the ring-shaped member 1 is not limited to the form shown in Fig. 3 and can be modified as appropriate. For example, as shown in Fig. 4, it may be a form 6 in which it is formed long along the circumferential direction of the ring-shaped member 1. In this case, the tip of the protrusion 2 is linear and extends in the circumferential direction of the ring-shaped member 1. Note that the linear shape may mean that the tip is arc-shaped, flat, or linear with width. The tip of this protrusion 2 may be a circumferential surface that follows the outer diameter of the ring-shaped member 1.

[0018] The tip of the protrusion 2 need not be linear as shown in the figure, but may be dotted, cylindrical, cross-shaped, or otherwise modified as appropriate.

[0019] The ring-shaped member 1 contacts the nanocrystalline alloy ribbon and applies an external force directly to the nanocrystalline alloy ribbon. Although the nanocrystalline alloy ribbon has a brittle property, it has a high hardness, so the ring-shaped member 1 is preferably made of a wear-resistant tool steel material or a superhard material. For example, the tool steel material may be SS material, SC material, SKD material, or SKS material.

[0020] A side view of the cracking roll of the present disclosure is shown in Fig. 2. This cracking roll 55 is made by arranging a plurality of ring-shaped members 1, with spacer materials 4 disposed between the ring-shaped members 1. In Fig. 2, 28 ring-shaped members 1 are used. The spacer materials 4 used are ring-shaped. The spacer materials 4 need not be ring-shaped as long as they can set the intervals.

[0021] Here, two key grooves 3 are formed on the inner circumference of the ring-shaped member 1. The ring-shaped member 1 is attached to the shaft material of the cracking roll 55 by aligning the key grooves 3 with the engagement portion provided on the shaft material of the cracking roll. FIG. 2 shows the shaft portion 58. The shaft material to which the ring-shaped member 1 is attached can be inserted into the shaft portion 58 for use. The position of the key groove 3 is provided at a position that allows the position of the protrusion 2 of the ring-shaped member 1 to be adjusted. In other words, the position of the protrusion 2 can be made different when the ring-shaped member 1 is attached to the shaft material of the cracking roll using the first key groove 3 and when the ring-shaped member 1 is attached to the shaft material of the cracking roll using the second key groove 3. In other words, the protrusions can be shifted between adjacent ring-shaped members so that they are not continuous in the axial direction of the ring-shaped members. A third or fourth key groove 3 may be provided.

[0022] The cracking roll 55 of the present disclosure is configured so that the width in the axial direction matches the width of the nanocrystalline alloy ribbon. Then, while the cracking roll rotates, it continuously comes into contact with the nanocrystalline alloy ribbon in the casting direction, and forms cracks in the nanocrystalline alloy ribbon. At this time, the direction in which the cracking roll rotates is along the casting direction of the nanocrystalline alloy ribbon.

[0023] According to the cracking roll 55 of the present disclosure, the number of ring-shaped members 1 can be adjusted to match the width of the nanocrystalline alloy ribbon. Furthermore, by changing the width of the spacer material 4, it is possible to adjust the interval Px (see FIG. 9, which will be described later) between the protrusions 2 of the ring-shaped member 1. Here, the interval Px is the interval between the protrusions 2 in the nanocrystalline alloy ribbon in the direction perpendicular to the casting direction of the nanocrystalline alloy ribbon (X direction), and is the distance from the end of one protrusion to the end of the other protrusion. In addition, by preparing a plurality of ring-shaped members 1 with different intervals (circumferential intervals) between the protrusions 2 of the ring-shaped members 1, it is possible to adjust the interval Py (see FIG. 9 , which will be described later) between the protrusions 2 of the ring-shaped members 1. Here, the interval Py is the interval in the casting direction of the nanocrystalline alloy ribbon among the intervals between the protrusions in the nanocrystalline alloy ribbon, and is the center-to-center distance between one protrusion and the other protrusion.

[0024] That is, according to the present disclosure, when the width of the nanocrystalline alloy ribbon is different, the width of the cracking roll can be easily adjusted. Also, the crack pattern can be changed by adjusting the thickness of the spacer material. Also, the crack pattern can be changed by changing the interval between the protrusions of the ring-shaped member or the shape of the protrusions. Also, the cracking roll can be configured by combining ring-shaped members with different protrusions, and the crack pattern can be changed in various ways.

[0025] According to the present disclosure, it is easy to manufacture a cracking roll according to the morphology of the cracks in the nanocrystalline alloy ribbon, and it is easy to change the configuration of the cracking roll according to the desired morphology of the cracks in the nanocrystalline alloy ribbon.

[0026] The nanocrystalline alloy ribbon of the present disclosure can be produced by a production method including a step of rapidly cooling a molten alloy to obtain an amorphous alloy ribbon capable of nanocrystallization, and a heat treatment step of heat treating the amorphous alloy ribbon at a crystallization onset temperature or higher to form fine crystal grains.

[0027] The temperature of the heat treatment is set according to the alloy composition. The fine crystal grains are, for example, Fe with a body-centered cubic lattice structure in which Si and other elements are dissolved. The fine crystal grains can be analyzed using X-ray diffraction and a transmission electron microscope.

[0028] In the nanocrystalline alloy ribbon, at least 50% by volume of the nanocrystalline alloy ribbon is made up of fine crystal grains having an average grain size of 100 nm or less measured at the maximum dimension. The portion of the nanocrystalline alloy other than the fine crystal grains is mainly amorphous. The proportion of the fine crystal grains may be substantially 100% by volume.

[0029] The above-mentioned quenching can be performed by a single-roll method in which the molten alloy is discharged onto a rotating chill roll and rapidly solidified. The direction along the rotation direction of the chill roll is the casting direction of the nanocrystalline alloy ribbon. The casting direction of this nanocrystalline alloy ribbon is also the longitudinal direction of the nanocrystalline alloy ribbon, and the length can be, for example, 20,000 m.

[0030] The nanocrystalline alloy ribbon preferably has a composition represented by the following general formula: General formula: (Fe 1-a Ma) 100-x-y-z-α-β-γ Cu x S y B z M' α M” β X γ (atom%)

[0031] 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. 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.

[0032] In the present disclosure, the nanocrystalline alloy ribbon will be described by taking as an example an Fe-Cu-Nb-Si-B based nanocrystalline alloy ribbon (FT-3 manufactured by Proterial Co., Ltd.).

[0033] In addition, as the nanocrystalline alloy ribbon of the present disclosure, it is preferable to use a nanocrystalline alloy ribbon obtained by subjecting an amorphous alloy ribbon capable of nanocrystallization to a heat treatment for nanocrystallization while applying tension thereto.

[0034] By applying tension to the amorphous alloy ribbon capable of nanocrystallization, it is possible to adjust the AC relative magnetic permeability μr of the nanocrystalline alloy ribbon. It is preferable to obtain a nanocrystalline alloy ribbon having an AC relative magnetic permeability μr of 100 to 2000 measured at a frequency of 128 kHz by this process.

[0035] In the present disclosure, the tension applied to the amorphous alloy ribbon in the casting direction is preferably 1.0 N to 50.0 N, more preferably 2.0 N to 40.0 N, and particularly preferably 3.0 N to 35.0 N. When the tension is 1.0 N or more, the magnetic permeability can be sufficiently reduced. When the tension is 50.0 N or less, breakage of the amorphous alloy ribbon or nanocrystalline alloy ribbon can be further suppressed.

[0036] In the heat treatment for nanocrystallization in this embodiment, the amorphous alloy ribbon is heated to an ultimate temperature equal to or higher than the crystallization temperature Tc1 (for example, 430°C or higher). This advances nanocrystallization in the structure of the alloy ribbon. The ultimate temperature is preferably 430°C to 640°C. When the attained temperature is 640°C or less (particularly when the B content is 10 atomic % or more and 20 atomic % or less), for example, the frequency of precipitation of Fe-B compounds that may deteriorate the soft magnetic properties (Hc, Bs, etc.) of the nanocrystalline alloy ribbon can be further reduced. It is also preferable that the set ultimate temperature and the temperature of the heat transfer medium are set to the same temperature.

[0037] The thickness of the amorphous alloy ribbon capable of nanocrystallization in this embodiment is preferably in the range of 10 μm to 50 μm. If it is less than 10 μm, the mechanical strength of the alloy ribbon itself is low, making it difficult to stably cast a long alloy ribbon. If it exceeds 50 μm, a part of the alloy is likely to crystallize, and the characteristics may deteriorate. The thickness of the amorphous alloy ribbon is more preferably 11 μm to 30 μm, and further preferably 12 μm to 27 μm.

[0038] The width of the amorphous alloy ribbon is not particularly limited, but is preferably 5 mm to 300 mm. When the width of the amorphous alloy ribbon is 5 mm or more, the manufacturing suitability of the amorphous alloy ribbon is excellent. When the width of the amorphous alloy ribbon is 300 mm or less, the uniformity of nanocrystallization is further improved in the process of obtaining a nanocrystalline alloy ribbon. The width of the amorphous alloy ribbon is preferably 200 mm or less.

[0039] The nanocrystalline alloy ribbon has a property of being more brittle than the amorphous alloy ribbon. Therefore, when a crack is formed in the nanocrystalline alloy ribbon by directly applying an external force, the crack can be formed with a small external force. In addition, the crack can be formed without substantially forming unevenness on the surface. Therefore, the flat surface state of the nanocrystalline alloy ribbon can be made good.

[0040] A cross-sectional view of an example in which an adhesive layer is disposed on one side of the nanocrystalline alloy ribbon having cracks formed therein according to the present disclosure is shown in Fig. 10. Fig. 10 shows a nanocrystalline alloy ribbon 20, an adhesive layer 10 attached to one side of the nanocrystalline alloy ribbon, and a resin sheet 15 attached to the adhesive layer 10. A crack 21 is formed in the nanocrystalline alloy ribbon 20, and the nanocrystalline alloy ribbon 20 is divided into small pieces 22. The adhesive layer 10 includes adhesives 12 on both sides of a support 11, the nanocrystalline alloy ribbon 20 is attached to one adhesive 12, and the resin sheet 15 is attached to the other adhesive 12.

[0041] The support 11 is a strip-shaped film member formed in an elongated shape, for example, a rectangular film member. The support 11 is formed using a flexible resin material. As the resin material, polyethylene terephthalate (PET) can be used.

[0042] For example, a pressure-sensitive adhesive can be used as the adhesive 12. For example, known adhesives such as acrylic adhesives, silicone adhesives, urethane adhesives, synthetic rubber, and natural rubber can be used as the adhesive 12. Acrylic adhesives are preferable as the adhesive 12 because they have excellent heat resistance and moisture resistance and can bond a wide range of materials.

[0043] It is preferable that the nanocrystalline alloy ribbon 20 and the adhesive layer 10 have shapes that satisfy the following relationship. 0.2mm≦(Width A-Width B)≦3mm The width A is a dimension related to the adhesive layer 10, and more preferably a dimension related to a region in the adhesive layer 10 where the adhesive 12 to which the nanocrystalline alloy ribbon 20 is adhered is provided. The width B is a dimension related to the nanocrystalline alloy ribbon 20. When the adhesive 12 is provided on the entire surface of the support 11 of the adhesive layer 10, the width A is a dimension related to the adhesive layer 10 or the support 11.

[0044] Here, the lower limit of (width A - width B) is preferably 0.5 mm, and more preferably 1.0 mm, and the upper limit of (width A - width B) is preferably 2.5 mm, and more preferably 2.0 mm.

[0045] Moreover, the nanocrystalline alloy ribbons 20 and the adhesive layer 10 are arranged so as to satisfy another relationship of the following formula. 0mm<gap a and 0mm<gap b

[0046] Gap a and gap b are the distances from the end of the adhesive layer 10 to the end of the nanocrystalline alloy ribbon 20. Specifically, gap a is the distance from the first adhesive layer end 10X of the adhesive layer 10 to the first ribbon end 20X of the nanocrystalline alloy ribbon 20. Gap b is the distance from the second adhesive layer end 10Y of the adhesive layer 10 to the second ribbon end 20Y of the nanocrystalline alloy ribbon 20.

[0047] The first ribbon end 20X is an end on the same side as the first adhesive layer end 10X of the nanocrystalline alloy ribbon 20. The second adhesive layer end 10Y is an end of the adhesive layer 10 opposite to the first adhesive layer end 10X. The second ribbon end 20Y is an end on the same side as the second adhesive layer end 10Y of the nanocrystalline alloy ribbon 20.

[0048] The width A, the width B, the gap a, and the gap b are dimensions in a direction intersecting, more preferably perpendicular to, the casting direction of the nanocrystalline alloy ribbon 20. The casting direction of the nanocrystalline alloy ribbon 20 and the extending direction of the adhesive layer 10 are the same direction. In addition, the casting direction of the nanocrystalline alloy ribbon 20 and the longitudinal direction of the nanocrystalline alloy ribbon 20 are the same direction.

[0049] A manufacturing method for forming cracks in the nanocrystalline alloy ribbon 20 according to the present disclosure will be described with reference to Fig. 11. Fig. 11 is a schematic diagram for explaining a manufacturing method for forming cracks in the nanocrystalline alloy ribbon 20 according to an embodiment.

[0050] 11 is mainly provided with a first unwinding roll 510, a first winding roll 520, a second unwinding roll 530, an attaching roll 540, a cracking roll 550, a flattening roll 560, and a third winding roll 570, from upstream to downstream in the manufacturing process. The manufacturing apparatus 500 may further be provided with a plurality of guide rolls 580. Note that the guide rolls 580 may be arranged at positions not shown as necessary.

[0051] FIG. 12 is a cross-sectional view illustrating the configuration of the laminate supplied from the first unwinding roll 510. As shown in FIG. 12, a laminate in which adhesive 12 is provided on each of first surface 11A and second surface 11B of adhesive layer 10, and resin sheet 15 is laminated on each of them, is wound around first unwinding roll 510. Resin sheet 15 arranged on first surface 11A is a protective sheet, and resin sheet 15 arranged on second surface 11B is also referred to as a liner. Resin sheet 15 arranged on first surface 11A is a sheet having a smaller thickness than resin sheet 15 arranged on second surface 11B.

[0052] The resin sheet 15 arranged on the first surface 11A of the laminate unwound from the first unwinding roll 510 is peeled off. The peeled resin sheet 15 is taken up by the first winding roll 520, as shown in FIG.

[0053] The laminate from which the resin sheet 15 arranged on the first surface 11A has been peeled off is guided to the laminating roll 540 by a plurality of guide rolls 580. The nanocrystalline alloy ribbon 20 unwound from the second unwinding roll 530 is further guided to the laminating roll 540. No cracks 21 are formed in the nanocrystalline alloy ribbon 20 guided to the laminating roll 540.

[0054] The laminating roll 540 presses and adheres the nanocrystalline alloy ribbon 20 to the laminate from which the resin sheet 15 has been peeled off. Specifically, the laminate and the nanocrystalline alloy ribbon 20 are guided between two rolls arranged opposite to each other, and the nanocrystalline alloy ribbon 20 is pressed and adhered to the adhesive material 12 on the first surface 11A of the adhesive layer 10 by using the two rolls.

[0055] The nanocrystalline alloy ribbons 20 may be arranged so that their centers coincide with the adhesive layer 10 in the width direction, or may be arranged so that their centers are separated. In this case, they are arranged so as to satisfy the relationships of 0 mm<gap a and 0 mm<gap b (see FIG. 10). The laminate to which the nanocrystalline alloy ribbons 20 are adhered is led from the laminating roll 540 to the cracking roll 550, as shown in FIG. 11. This cracking roll 550 is composed of a cracking roll provided with protrusions (the cracking roll 55 of the present disclosure is used) and a roll not provided with protrusions.

[0056] The cracking roll 550 forms cracks 21 in the nanocrystalline alloy ribbon 20 bonded to the adhesive layer 10. Specifically, the laminate to which the nanocrystalline alloy ribbon 20 is bonded is guided between two rolls arranged opposite to each other, and the cracking roll with protrusions (the cracking roll 55 of the present disclosure is used) of the two rolls is brought into direct contact with the nanocrystalline alloy ribbon 20 to form cracks 21 (see FIG. 10). Here, the protrusions of the cracking roll come into contact with the nanocrystalline alloy ribbon and apply pressure to form cracks.

[0057] Of the two rolls, the roll without the protrusions is disposed on the laminate side from which the resin sheet 15 has been peeled off. The nanocrystalline alloy ribbon 20 in which the cracks 21 have been formed contains a plurality of small pieces 22 (see FIG. 10 ). The plurality of small pieces 22 are adhered to the adhesive layer 10.

[0058] In the formation of cracks using the cracking roll 550, it is preferable to further form cracks that connect the plurality of cracks 21 in a network-like manner. Specifically, it is preferable to have a process of pressing the cracking roll 550 against the nanocrystalline alloy ribbon 20 to form the plurality of cracks 21, and then forming cracks that connect the plurality of cracks 21 in a network-like manner.

[0059] For example, after applying an external force directly to the nanocrystalline alloy ribbon 20 using the cracking roll 550 to form cracks 21, a second external force may be applied by bending or winding the nanocrystalline alloy ribbon 20 to form cracks that connect the multiple cracks 21 in a mesh-like pattern. The cracks that connect the cracks 21 (magnetic gaps that connect the cracks) are formed with the cracks 21 as starting points of brittle fracture and / or crack fracture.

[0060] The laminate guided from the cracking roll 550 to the flattening roll 560 is subjected to flattening treatment by the flattening roll 560. The flattening roll 560 is also referred to as a shaping roll.

[0061] Specifically, the laminate is guided between two rolls arranged opposite to each other in the flattening roll 560, and the laminate is sandwiched between the two rollers and pressed. This flattens the surface of the nanocrystalline alloy ribbon 20 on which the cracks 21 are formed.

[0062] A flattening process is performed to form cracks in the nanocrystalline alloy ribbons 20, and a sheet-shaped magnetic member 100 having an adhesive layer 10 on one surface is obtained (see FIG. 10). The adhesive layer 10 has a resin sheet 15 on one surface. The sheet-shaped magnetic member 100 is guided to a third winding roll 570 via a guide roll 580. The sheet-shaped magnetic member 100 is wound around the third winding roll 570.

[0063] FIG. 13 is a schematic diagram illustrating an embodiment of a method for producing a sheet-shaped magnetic member 300 in which nanocrystalline alloy ribbons 20 having cracks formed therein are stacked. The sheet-shaped magnetic member 300 in which the nanocrystalline alloy ribbons 20 having cracks are stacked can be manufactured by using a manufacturing apparatus 600 shown in Fig. 13. Fig. 13 shows the manufacturing apparatus 600 for manufacturing the sheet-shaped magnetic member 300 including five layers of the nanocrystalline alloy ribbons 20.

[0064] The manufacturing apparatus 600 is mainly provided with a supply roll 601, a resin sheet winding roll 602, a first magnetic sheet unwinding roll 611, a first winding roll 612, a first pasting roll 613, a second magnetic sheet unwinding roll 621, a second winding roll 622, a second pasting roll 623, a third magnetic sheet unwinding roll 631, a third winding roll 632, a third pasting roll 633, a fourth magnetic sheet unwinding roll 641, a fourth winding roll 642, a fourth pasting roll 643, a fifth magnetic sheet unwinding roll 651, a fifth pasting roll 653, a flattening roll 663, and a multilayer magnetic sheet winding roll 670, from the upstream to the downstream of the manufacturing process. The manufacturing apparatus 600 may further be provided with a plurality of guide rolls 680. The guide roll 680 may be arranged at a position not shown as necessary.

[0065] The manufacturing apparatus 600 may manufacture the sheet-shaped magnetic member 300 having two or more and four or less layers of nanocrystalline alloy ribbons 20. Also, the sheet-shaped magnetic member 300 may be manufactured having six or more layers of nanocrystalline alloy ribbons 20. In this case, the number of the above-mentioned first magnetic sheet unwinding rolls 611, etc. is changed according to the number of nanocrystalline alloy ribbons 20. Also, instead of the sheet-shaped magnetic member 100 unwound from the first magnetic sheet unwinding roll 611, etc., a sheet-shaped magnetic member having multiple layers of nanocrystalline alloy ribbons can be unwound to form a multilayer structure.

[0066] There is no particular upper limit on the number of layers. The number of layers may be determined as appropriate. However, when winding the sheet-shaped magnetic member 300 in which the nanocrystalline alloy ribbons 20 are laminated, if the number of layers is large, it may be difficult to wind the sheet-shaped magnetic member 300 or the sheet-shaped magnetic member 300 in which the nanocrystalline alloy ribbons 20 are laminated may cause a defective shape during winding. Therefore, when winding the sheet-shaped magnetic member 300 in which the nanocrystalline alloy ribbons 20 are laminated, the number of layers is preferably 30 or less. More preferably, it is 25 or less, more preferably 20 or less, more preferably 15 or less, and more preferably 10 or less.

[0067] As shown in FIG. 12, a laminate in which a resin sheet 15 is laminated on a first surface 11A and a second surface 11B of an adhesive layer 10 is wound around the supply roll 601. The resin sheet 15 arranged on the first surface 11A of the laminate unwound from the supply roll 601 is peeled off. The peeled resin sheet 15 is taken up by a resin sheet take-up roll 602, as shown in FIG.

[0068] The laminate from which the resin sheet 15 arranged on the first surface 11A has been peeled off is guided to a first laminating roll 613 by a guide roll 680. The sheet-shaped magnetic member 100 unwound from a first magnetic sheet unwinding roll 611 is further guided to the first laminating roll 613.

[0069] The first laminating roll 613 presses and adheres the sheet-shaped magnetic member 100 to the laminate from which the resin sheet 15 has been peeled off. Specifically, the laminate and the sheet-shaped magnetic member 100 are guided between two rolls arranged opposite to each other, and the two rolls are used to press and adhere the nanocrystalline alloy ribbons 20 of the sheet-shaped magnetic member 100 to the first surface 11A of the adhesive layer 10 of the laminate.

[0070] The resin sheet 15 of the sheet-shaped magnetic member 100 adhered by the first laminating roll 613 is peeled off from the sheet-shaped magnetic member 100 and taken up by the first winding roll 612. The laminate after the resin sheet 15 is taken up by the first winding roll 612 is guided to the second laminating roll 623. The sheet-shaped magnetic member 100 unwound from the second magnetic sheet unwinding roll 621 is further guided to the second laminating roll 623.

[0071] The second laminating roll 623 presses and adheres the sheet-shaped magnetic member 100 onto the laminate delivered from the first laminating roll 613. Specifically, the laminate and the sheet-shaped magnetic member 100 are led between two rolls arranged opposite to each other, and the nanocrystalline alloy ribbons 20 of the sheet-shaped magnetic member 100 are pressed and adhered onto the second surface 11B of the adhesive layer 10 of the laminate by using the two rolls.

[0072] The resin sheet 15 of the sheet-shaped magnetic member 100 adhered by the second laminating roll 623 is peeled off from the sheet-shaped magnetic member 100 and taken up by the second winding roll 622. The laminate after the resin sheet 15 has been taken up by the second winding roll 622 is guided to a third laminating roll 633. The sheet-shaped magnetic member 100 unwound from a third magnetic sheet unwinding roll 631 is further guided to the third laminating roll 633.

[0073] Similarly, the third laminating roll 633, the fourth laminating roll 643, and the fifth laminating roll 653 are used to laminate the nanocrystalline alloy ribbons into five layers. The laminate guided from the fifth laminating roll 653 to the flattening roll 663 is subjected to flattening treatment by the flattening roll 663 .

[0074] As described above, the nanocrystalline alloy ribbons 20 and the adhesive layer 10 are preferably arranged so as to satisfy the relationships of 0 mm<gap a and 0 mm<gap b (see FIG. 10). However, in the lamination process of the sheet-shaped magnetic member 100 and the laminate, a positional deviation may occur. When this positional deviation occurs, the relationship between the nanocrystalline alloy ribbons 20 and the adhesive layer 10 may be such that, for example, the gap a becomes negative. In other words, an end of the nanocrystalline alloy ribbon 20 may protrude from an end of the adhesive layer 10 on one side of the nanocrystalline alloy ribbon 20. Even if an end of the nanocrystalline alloy ribbon 20 protrudes beyond the end of the adhesive layer 10 on one side of the nanocrystalline alloy ribbon 20, the nanocrystalline alloy ribbon 20 can maintain its adherence to the adhesive layer 10 as long as the relationship between the nanocrystalline alloy ribbon 20 and the adhesive layer 10 on the other side of the nanocrystalline alloy ribbon 20 satisfies the relationship 0 mm<gap a and 0 mm<gap b (see Figure 10).

[0075] The sheet-shaped magnetic member 300 is guided to the multilayered magnetic sheet take-up roll 670 via a guide roll 680. The sheet-shaped magnetic member 300 is taken up by the multilayered magnetic sheet take-up roll 670. Note that, other than the method of taking up the sheet-shaped magnetic member 300 by the multilayered magnetic sheet take-up roll 670, the sheet-shaped magnetic member 300 may be cut to a required length.

[0076] The laminate after the flattening process becomes the sheet-shaped magnetic member 300 shown in Fig. 14. The sheet-shaped magnetic member 300 shown in Fig. 14 is formed by laminating nanocrystalline alloy ribbons 20 via adhesive layers 10, and includes resin sheets 15 as the bottom and top layers. The sheet-shaped magnetic member 300 is a laminate of five layers of nanocrystalline alloy ribbons 20. The number of layers of nanocrystalline alloy ribbons 20 in the sheet-shaped magnetic member 300 can be set as appropriate.

[0077] For example, a sheet-shaped magnetic member having a plurality of five layers as shown in Fig. 14 may be produced, and the five-layer sheet-shaped magnetic members may be stacked to produce a sheet-shaped magnetic member having a large number of stacked nanocrystalline alloy ribbons 20. Moreover, a sheet-shaped magnetic member having a larger area may be produced by arranging the sheet-shaped magnetic members side by side.

[0078] In the sheet-shaped magnetic member of the present disclosure, the number of layers of the nanocrystalline alloy ribbons 20 is preferably 10 or more. More preferably, the number is 15 or more, more preferably 20 or more, and even more preferably 25 or more. There is no particular need to set an upper limit, and the required number of layers may be stacked.

[0079] The sheet-like magnetic member of the present disclosure may have another magnetic material, a metal foil such as aluminum, a resin sheet, or the like attached to the bottom or top layer.

[0080] The sheet-shaped magnetic member of the present disclosure can be formed into a desired size and stacked in the required number to form a magnetic sheet or core material for contactless charging.

[0081] Example 1 [Manufacturing of nanocrystalline alloy ribbons] A nanocrystalline alloy ribbon (Fe-Cu-Nb-Si-B alloy) was produced by applying tension to the amorphous alloy ribbon (Fe-Cu-Nb-Si-B alloy). The tension applied to the amorphous alloy ribbon was 40 MPa. The temperature reached by the amorphous alloy ribbon in the heat treatment was 640°C. The nanocrystalline alloy ribbon had a thickness of 16 μm and a width of 30 mm. The nanocrystalline alloy ribbon in the embodiment is equivalent to FT-3 manufactured by Proterial Co., Ltd. [Cracking Roll] A link-shaped member 1 having the structure shown in Fig. 1 and Fig. 3 was prepared. The ring-shaped member 1 had an outer diameter of 31 mm and a thickness of 0.8 mm, and was made of SKD tool steel. Next, as shown in Fig. 2, a cracking roll was produced by arranging a plurality of ring-shaped members 1 with a spacer material 4 having a thickness of 0.6 mm sandwiched therebetween. At this time, the ring-shaped members 1 were attached so that the protrusions of adjacent ring-shaped members 1 were shifted by half a pitch with respect to the circumferential pitch of the protrusions so that they were not aligned in a straight line in the axial direction. The thickness of the spacer material is preferably 0.4 mm or more and 2 mm or less.

[0082] Fig. 9 is a schematic diagram showing the state of the contact area when this cracking roll comes into contact with the nanocrystalline alloy ribbon 20. Fig. 9 shows the surface of the nanocrystalline alloy ribbon, and the horizontal bar 7 shows the state in which the tip of the protrusion of the cracking roll comes into contact with the nanocrystalline alloy ribbon. In other words, the horizontal bar 7 shows the shape in which the tip of the protrusion 2 of the ring-shaped member 1 comes into contact with the nanocrystalline alloy ribbon 20. In the figure, S corresponds to the thickness of the spacer material.

[0083] In this embodiment, the horizontal bars 7 face in one direction. This one direction is referred to as the X direction. The X direction is a direction perpendicular to the casting direction of the nanocrystalline alloy ribbon 20. The interval Px between the horizontal bars 7 in the X direction is 2 mm. In other words, among the intervals between the protrusions in the nanocrystalline alloy ribbon, the interval Px in the direction perpendicular to the casting direction of the nanocrystalline alloy ribbon is 2 mm.

[0084] In addition, the Y direction in the figure is the casting direction of the nanocrystalline alloy ribbon 20. In the Y direction, the interval Py between the horizontal bars 7 is set to 1.6 mm. In other words, among the intervals between the protrusions in the nanocrystalline alloy ribbon, the interval Py in the casting direction of the nanocrystalline alloy ribbon is 1.6 mm. The interval between the horizontal bars 7 in the Y direction is preferably 1 mm or more and 2 mm or less. As will be described later, this embodiment is configured to form a crack having an elongated shape in the X direction, and has a relationship of distance Px>distance Py.

[0085] [Manufacturing of sheet-shaped magnetic members] Using this cracking roll, the sheet-shaped magnetic member 100 shown in Fig. 10 was produced by the production method shown in Fig. 11. The state of cracks in the nanocrystalline alloy ribbons 20 of the produced sheet-shaped magnetic member 100 was observed. For the observation, a USB camera L-836 (magnification 20) manufactured by Hozan Corporation and a stereo microscope SZ2-ILST (magnification 10 to 40) manufactured by Olympus Corporation were used. In addition, the observation was performed by transmitting light from the back side of the observation surface.

[0086] An observation photograph is shown in Fig. 6. A copy of the crack lines is shown in Fig. 7. Fig. 7 is a copy of an area of ​​15 mm (X direction) × 11 mm (Y direction) of the nanocrystalline alloy ribbon in Fig. 6. As can be seen from Figs. 6 and 7, the small pieces in this example have an elongated shape in the horizontal direction (X direction). Here, the X direction is a direction perpendicular to the casting direction of the nanocrystalline alloy ribbon, and the Y direction is the casting direction of the nanocrystalline alloy ribbon.

[0087] 6 and 7 were used to measure the size of the particles. An example of a small piece is shown in Figure 8. The maximum value of the small piece in the Y direction is length L, and the maximum value of the small piece in the X direction is length W. At this time, small pieces PW were defined as pieces with length W > length L and length W of 0.2 mm or more, and small pieces PL were defined as pieces with length L ≥ length W and length L of 0.2 mm or more, and the number of each was calculated. The number PWN of small pieces PW was 450, and the number PLN of small pieces PL was 100. As a result, PWN / (PWN+PLN) = 82%. This PWN / (PWN+PLN) is preferably 60% or more. It is preferable that it is 70% or more, and more preferably 80% or more. The maximum value of the length W was 6.8 mm. The length W is preferably 10 mm or less, more preferably 8 mm or less, and further preferably 7 mm or less. Furthermore, the number PWMN of small pieces where length W > length L and length W was 1.6 mm or more was 44. This number PWMN is preferably 10 or more. Furthermore, 20 or more is preferable, and 30 or more is more preferable. Furthermore, PWMN / PWN was 10%. This PWMN / PWN is preferably 5% or more. This observation is listed in Table 1 as Observation A. Another area was observed in the same manner, and the results are shown in Table 1 as Observation B.

[0088] [Table 1]

[0089] The nanocrystalline alloy ribbon 20 of the present disclosure was divided into small pieces by cracks, and many small pieces elongated in the X direction (the direction perpendicular to the casting direction of the nanocrystalline alloy ribbon) were observed. The small pieces have a basic shape of a hexagon elongated in the X direction, and are honeycomb-shaped in which these elongated hexagons are combined. Among the opposing vertices of the hexagon, the distance between the first vertices is longer than the distance between the other vertices, and the direction between the first vertices is along the direction perpendicular to the casting direction of the nanocrystalline alloy ribbon. In addition, in the hexagon, an arc-shaped crack is formed around the side parallel to the direction between the first vertices. In addition, the hexagon partially includes a crack connecting the first vertices. Note that this hexagon corresponds to a shape obtained by connecting the short points of the rod-shaped bar 7 in FIG. 9.

[0090] A sheet-like magnetic member 300 having five layers of nanocrystalline alloy ribbons 20 was produced by the manufacturing method shown in FIG. 13 using the sheet-like magnetic member 100 including the nanocrystalline alloy ribbons having the cracks formed therein according to the present disclosure. Furthermore, five of these sheet-like magnetic members 300 were stacked to produce a sheet-like magnetic member having 25 layers of nanocrystalline alloy ribbons 20. A side view of the sheet-like magnetic member 700 having 25 layers of nanocrystalline alloy ribbons is shown in FIG. 15. In this sheet-like magnetic member 700, three sheet-like magnetic members 300 were arranged in parallel, two sheet-like magnetic members 300 were arranged in parallel on top of them with a half pitch shift in the width direction, and three sheet-like magnetic members 300 were arranged in parallel on top of them as in the first layer, and five were stacked in the stacking direction in the same manner. The length direction was about 60 mm. In this 25-layer sheet-like magnetic member 700, two adhesive layers 10 were provided between the five sheet-like magnetic members 300.

[0091] The characteristics of the 25-layer sheet-shaped magnetic member 700 of this example were evaluated. As a comparative example, a sheet-shaped magnetic member was used in which 25 layers were laminated together with adhesive layers interposed therebetween without forming any cracks. The measuring device 800 used in the evaluation will be described with reference to Fig. 19. Fig. 19 is a diagram illustrating the measuring device 800 used in the evaluation of the magnetic sheet.

[0092] The measuring device 800 is provided with an LCR meter 810, a measuring coil 820, and an aluminum board 830. The LCR meter 810 is connected to the measuring coil 820, and is a device that measures Ls (inductance (H)) and Rs (resistance (Ω)) of the sheet-shaped magnetic member 840 together with the measuring coil 820. The LCR meter 810 used was an E4980A manufactured by Keysight Corporation. Note that the sheet-shaped magnetic member 700 of the present disclosure and a sheet-shaped magnetic member of a comparative example were arranged as the sheet-shaped magnetic member 840 and evaluated.

[0093] The measuring coil 820 is a coil disposed together with the aluminum board 830, sandwiching the sheet-like magnetic member 840 therebetween. The diameter of the measuring coil is 50 mm. At a frequency of 85 kHz, the measuring coil 820 has an Ls of 3.5 μH and an Rs of 28 mΩ.

[0094] The aluminum board 830 is a plate member formed in a rectangular shape. Specifically, the aluminum board 830 is a plate member having a square shape with each side measuring 60 mm and a thickness of 2 mm.

[0095] Furthermore, Q is calculated based on Ls and Rs measured by the measuring device 800. The calculation is performed using the formula Q=Ls / Rs×2πf, where f is the frequency (Hz).

[0096] Next, the measurement results by the measurement device 800 will be described with reference to Fig. 16 to Fig. 18. Fig. 16 is a graph showing the value of Q calculated based on the measurement results. Fig. 17 is a graph showing the measured value of Ls. Fig. 18 is a graph showing the measured value of Rs.

[0097] In Fig. 16 to Fig. 18, the embodiment is indicated by Crack 25L, and the comparative example is indicated by Non crack 25L. In Fig. 16, the horizontal axis indicates the frequency (kHz) used in the measurement, and the vertical axis indicates the Q value. In Fig. 17, the horizontal axis indicates the frequency (kHz) used in the measurement, and the vertical axis indicates the Ls (H) value. In Fig. 18, the horizontal axis indicates the frequency (kHz) used in the measurement, and the vertical axis indicates the Rs (Ω) value.

[0098] 16, the Q value of the embodiment is higher than that of the comparative example at almost all frequencies. In other words, the Q value of the embodiment is larger than that of the comparative example at almost all frequencies.

[0099] The operating frequency used in a contactless charging circuit for an automobile is about 85 kHz, and the operating frequency used in a contactless charging circuit for a smartphone is about 128 kHz or 360 kHz. In other words, the sheet-like magnetic member of the embodiment is shown to have a high Q value at the operating frequencies used in a contactless charging circuit for an automobile or a contactless charging circuit for a smartphone. Therefore, the sheet-like magnetic member is useful for these applications.

[0100] As shown in FIG. 17, the Ls value decreases as the frequency increases. There was no significant difference between the Example and the Comparative Example. As shown in FIG. 18, the Rs value increases as the frequency increases overall. In high frequency regions, the increase in Rs with increasing frequency is greater than in low frequency regions. The higher the frequency region, the lower the Example is located compared to the Comparative Example. In other words, the Example has a smaller Rs value than the Comparative Example at frequencies above about 100 kHz. In the Example, Rs is small, and the Q value is improved by suppressing eddy current loss.

[0101] Since the cracking roll of the present disclosure can be manufactured by arranging ring-shaped members, it is easily understood that the crack shape of the nanocrystalline alloy ribbon 20 can be adjusted by adjusting the spacing between the ring-shaped members or changing the shape of the protrusions of the ring-shaped members. Furthermore, the sheet-shaped magnetic member of the present disclosure can be used as a magnetic sheet (for example, a magnetic sheet for contactless charging) or as a core material for inductance components.

Claims

1. forming an adhesive layer on a first surface of the nanocrystalline alloy ribbon, and directly applying a cracking roll to a second surface of the nanocrystalline alloy ribbon opposite to the first surface to form cracks in the nanocrystalline alloy ribbon, thereby producing a nanocrystalline alloy ribbon having cracks formed therein; A method for producing a sheet-like magnetic member, comprising stacking a plurality of nanocrystalline alloy ribbons having the cracks formed therein via the adhesive layer to produce a sheet-like magnetic member in which a plurality of nanocrystalline alloy ribbons are stacked, A method for manufacturing a sheet-shaped magnetic member, wherein the cracking roll comprises a plurality of ring-shaped members each having a plurality of protrusions on its outer peripheral surface, and the plurality of ring-shaped members are arranged in line in the axial direction.

2. The protrusion has a linear tip portion extending in an axial direction of the ring-shaped member, The method for producing a sheet-shaped magnetic member according to claim 1 , wherein the protrusions are provided at intervals in the circumferential direction.

3. The method for producing a sheet-shaped magnetic member according to claim 1 , wherein the protrusions are arranged so as to be offset so as not to be continuous between adjacent ring-shaped members when viewed in the axial direction of the ring-shaped members.

4. The method for producing a sheet-shaped magnetic member according to claim 1 , further comprising disposing a spacer material between the ring-shaped members.

5. The method for producing a sheet-shaped magnetic member according to claim 1 , wherein the spacer material has a thickness S of 0.4 mm or more and 2 mm or less.

6. The method for producing a sheet-shaped magnetic member according to claim 1, wherein the distance Py between the protrusions in the nanocrystalline alloy ribbon in the casting direction of the nanocrystalline alloy ribbon is 1 mm or more and 2 mm or less.

7. The method for manufacturing a sheet-shaped magnetic member according to claim 1, wherein, among the intervals between the protrusions in the nanocrystalline alloy ribbon, the relationship between the interval Px in a direction perpendicular to the casting direction of the nanocrystalline alloy ribbon and the interval Py in the casting direction of the nanocrystalline alloy ribbon is Px>Py.

8. a resin sheet is provided on an adhesive layer formed on a first surface of the nanocrystalline alloy ribbon; With the resin sheet provided, the cracking roll is directly applied to the second surface of the nanocrystalline alloy ribbon to form cracks in the nanocrystalline alloy ribbon; The method for producing a sheet-shaped magnetic member according to claim 1 , wherein the resin sheet is peeled off when stacking the plurality of nanocrystalline alloy ribbons having the cracks formed therein via the adhesive layer.

9. The method for producing a sheet-shaped magnetic member according to claim 1 , wherein the protrusion has a linear tip portion extending in a direction perpendicular to the casting direction.

10. The nanocrystalline alloy ribbon is divided into small pieces by the cracks, The method for producing a sheet-shaped magnetic member according to claim 1 , wherein the small pieces are elongated in a direction perpendicular to the casting direction.

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