Sheet-shaped magnetic member and manufacturing method for the same

Abstract

To provide a sheet-shaped magnetic member that solves the warping problem in cases where a large magnetic sheet in terms of thickness and area is to be formed.SOLUTION: Three or more magnetic thin bands are laminated to form a laminated substrate. Multiple laminated substrates are arranged side by side in a direction in which longer sides are adjacent to each other and shorter sides extend to form a plate-like shape, and the multiple laminated substrates are laminated in a lamination direction to form a panel substrate. The multiple panel substrates are laminated and arranged to form the sheet-shaped magnetic member. In the first panel substrate and the second panel substrate laminated on the first panel substrate, the lamination direction of the first panel substrate is reversed relative to the lamination direction of the second panel substrate.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a sheet-shaped magnetic member used in magnetic cores, inductors, magnetic shields, etc., and a method for manufacturing the same. [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] Special Publication No. 2019-522355 [Patent Document 4] China Utility Model Publication No. 209087527 Summary of the Invention [Problem to be solved by the invention]

[0008] Various applications of contactless charging are being considered. For example, one of them is an application to electric vehicles. It is preferable that parts to be mounted on electric vehicles are lightweight. Nanocrystalline alloy ribbons are materials that can be made thinner than other magnetic materials, such as ferrite materials. Therefore, it is preferable that the magnetic sheet to be mounted on an electric vehicle is a magnetic sheet using a nanocrystalline alloy ribbon. In addition, in the case of contactless charging of electric vehicles, the power to be transmitted is large and the transmission coil is also large compared to electronic devices such as mobile phones. For magnetic sheets for such applications, it is required to laminate the nanocrystalline alloy ribbons in multiple layers to increase the overall thickness of the nanocrystalline alloy ribbons in order to increase the magnetic flux density to be handled, and to provide a magnetic sheet with a large area to match the size of the corresponding coil.

[0009] Patent Document 3 describes a technique for arranging and laminating nanocrystalline alloy ribbons in a plate shape, while Patent Document 4 describes a structure in which amorphous nanocrystalline monomer plates in which amorphous nanocrystalline monomers are arranged are laminated. Thus, attempts have been made to increase the thickness and area of ​​magnetic sheets using nanocrystalline alloy ribbons. However, it has been found that in reality, when constructing a magnetic sheet having a large thickness and area, a problem of warping occurs.

[0010] The present disclosure provides a sheet-shaped magnetic member that solves the problem of warping when forming a magnetic sheet that is large in thickness and area. [Means for solving the problem]

[0011] The present disclosure relates to a sheet-like magnetic member comprising a plurality of laminated substrates each including three or more layers of magnetic ribbons formed in a band shape having a short side and a long side, the plurality of laminated substrates being arranged in a plate shape in a direction in which the short sides extend with the long sides adjacent to each other, and a plurality of panel substrates each including a plurality of laminated substrates arranged in a stacked manner in the stacking direction, The panel base is formed by laminating 15 or more layers of the magnetic ribbons, The sheet-shaped magnetic member is formed by laminating 40 or more layers of the magnetic ribbons, The sheet-shaped magnetic member includes a first panel base and a second panel base stacked on the first panel base, in which the stacking orientation of the first panel base and the stacking orientation of the second panel base are reversed. The present disclosure also provides a method for manufacturing a sheet-like magnetic member, comprising stacking three or more layers of magnetic ribbons formed in a band shape having short sides and long sides to form a laminated base, arranging a plurality of the laminated bases in a plate shape in a direction in which the short sides extend with the long sides adjacent to each other, and stacking a plurality of the laminated bases in the stacking direction to form a panel base, and stacking a plurality of the panel bases to form the sheet-like magnetic member, The panel base is formed by laminating 15 or more layers of the magnetic ribbons, The sheet-shaped magnetic member is formed by laminating 40 or more layers of the magnetic ribbons, This is a manufacturing method for a sheet-shaped magnetic member in which, when stacking a second panel base on a first panel base, the stacking orientation of the first panel base and the stacking orientation of the second panel base are reversed. Effect of the Invention

[0012] According to the present disclosure, it is possible to provide a sheet-shaped magnetic member that solves the problem of warping when forming a magnetic sheet that is large in thickness and area. [Brief description of the drawings]

[0013] [Figure 1] 1 is a conceptual diagram of a first embodiment of a sheet-shaped magnetic member according to the present disclosure. [Diagram 2] 4 is a conceptual diagram of a second embodiment of a sheet-shaped magnetic member according to the present disclosure. FIG. [Diagram 3] FIG. 13 is a conceptual diagram of a third embodiment of a sheet-shaped magnetic member according to the present disclosure. [Figure 4] 13 is a conceptual diagram illustrating the process of obtaining a sheet-shaped magnetic member according to a third embodiment of the present disclosure. [Diagram 5] FIG. 13 is a conceptual diagram of a fourth embodiment of a sheet-shaped magnetic member according to the present disclosure. [Figure 6] FIG. 2 is a conceptual diagram illustrating the configuration of a panel base according to the present disclosure. [Figure 7] FIG. 2 is a conceptual diagram illustrating the configuration of a panel base according to the present disclosure. [Figure 8] FIG. 1 is a cross-sectional view of one embodiment of a laminated substrate of the present disclosure. [Figure 9]1 is a cross-sectional view of a sheet material including a magnetic ribbon and an adhesive layer according to the present disclosure. [Figure 10] FIG. 1 is a plan view of one embodiment of a panel substrate of the present disclosure. [Figure 11] FIG. 1 is a side view of one embodiment of a panel substrate of the present disclosure. [Figure 12] FIG. 2 is a plan view of an embodiment of a sheet-shaped magnetic member according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] 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.

[0015] [Magnetic ribbon: Nanocrystalline alloy ribbon] The magnetic ribbon of the present disclosure is preferably a nanocrystalline alloy ribbon. Hereinafter, a case where a nanocrystalline alloy ribbon is used as the magnetic ribbon will be described. Note that when simply referred to as a magnetic ribbon, it is synonymous with a nanocrystalline alloy ribbon.

[0016] The nanocrystalline alloy ribbon 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.

[0017] 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.

[0018] 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 ratio of the fine crystal grains may be substantially 100% by volume.

[0019] 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. For example, in the nanocrystalline alloy ribbon produced by the single roll method, the casting direction is also the longitudinal direction of the nanocrystalline alloy ribbon, and the length can be, for example, 20,000 m. At this time, in the nanocrystalline alloy ribbon, the surface that was in contact with the chill roll is defined as the roll contact surface, and the surface that is not in contact with the chill roll is defined as the free solidification surface.

[0020] An example of the alloy composition of the amorphous alloy ribbon capable of nanocrystallization is a composition represented by the following general formula. For example, by heat treating an amorphous alloy ribbon having a composition represented by the following general formula, a nanocrystalline alloy ribbon having a composition represented by the following general formula can be obtained. 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%)

[0021] 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.

[0022] 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.).

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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. Here, the thickness of the amorphous alloy ribbon is equivalent to the thickness of the nanocrystalline alloy ribbon.

[0028] The nanocrystalline alloy ribbon of the present disclosure is preferably cracked and divided into small pieces. 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.

[0029] [One-layer sheet material of magnetic ribbon (nanocrystalline alloy ribbon)] Fig. 9 is a cross-sectional view of an embodiment of the magnetic ribbon of the present disclosure. In Fig. 9, the nanocrystalline alloy ribbon 20 is a single layer of sheet material 100, and corresponds to a cross section of the nanocrystalline alloy ribbon 20 in the width direction, and dimension B in the figure corresponds to the short side of the nanocrystalline alloy ribbon 20.

[0030] The sheet material 100 in Fig. 9 shows a nanocrystalline alloy ribbon 20, an adhesive layer 10 attached to one side of the nanocrystalline alloy ribbon 20, and a resin sheet 15 attached to the adhesive layer 10. Cracks 21 are 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] In addition, the nanocrystalline alloy ribbons 20 and the adhesive layer 10 are preferably disposed so as to satisfy another relationship of the following formula. 0mm<gap a and 0mm<gap b

[0036] 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.

[0037] 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.

[0038] 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.

[0039] As a method for forming cracks in the nanocrystalline alloy ribbon 20, a method for forming cracks in the nanocrystalline alloy ribbon by pressing a cracking roll against the nanocrystalline alloy ribbon is known. For example, the method disclosed in JP 2023-144882 A can be used.

[0040] [Laminated base] FIG. 8 is a cross-sectional view illustrating the configuration of one embodiment of the laminated substrate of the present disclosure. The laminated substrate 300 shown in FIG. 8 has a multilayer structure in which five nanocrystalline alloy ribbons 20, six adhesive layers 10, and two resin sheets 15 are laminated. The resin sheets 15 may be release films or protective films. When assembling a panel substrate using this laminated substrate 300, the resin sheets 15 are peeled off to expose the adhesive layers 10, which are then joined to another laminated substrate 300. In the present disclosure, a laminated substrate is one in which three or more magnetic ribbons are laminated.

[0041] The laminated substrate 300 has a structure in which at least the nanocrystalline alloy thin ribbons 20 and the adhesive layers 10 are alternately laminated. In addition, a resin sheet 15 is disposed on a first laminated end 301 and a second laminated end 302, which are both ends of the laminated substrate 300 in the lamination direction.

[0042] Specifically, from the bottom to the top of Figure 8, the structure has a resin sheet 15, an adhesive layer 10, a magnetic ribbon 20, an adhesive layer 10, a magnetic ribbon 20, an adhesive layer 10, a magnetic ribbon 20, an adhesive layer 10, a magnetic ribbon 20, an adhesive layer 10, a magnetic ribbon 20, an adhesive layer 10, a magnetic ribbon 20, an adhesive layer 10, and a resin sheet 15 stacked in that order.

[0043] The laminated substrate 300 can be manufactured in a long shape with a longitudinal length of, for example, 20,000 m. The width can be determined based on the width of the amorphous alloy ribbon that can be manufactured. A wider width improves productivity, but also poses manufacturing problems, so the width can be set in consideration of overall productivity. When manufacturing a panel substrate, the manufactured laminated substrate 300 can be cut to the required length and width as appropriate.

[0044] The laminated substrate 300 can be produced by stacking sheet materials 100 (see FIG. 9), each of which has one layer of nanocrystalline alloy ribbons 20 . For example, an adhesive layer 10 is formed on one surface of a resin sheet 15, and the nanocrystalline alloy ribbons 20 of a first sheet material 100 are bonded to the adhesive layer 10. Next, the resin sheet 15 of the bonded first sheet material 100 is peeled off to expose the adhesive layer 10. Then, the nanocrystalline alloy ribbons 20 of a second sheet material 100 are bonded to the adhesive layer 10. By repeating this process, a laminated substrate 300 having five layers of nanocrystalline alloy ribbons 20 can be produced.

[0045] Also, the first sheet material 100 is used as the lower layer, and the resin sheet 15 of the second sheet material 100 is peeled off to expose the adhesive layer 10, and the second sheet material 100 is then attached thereon. By repeating this process, a laminated substrate 300 having five layers of nanocrystalline alloy ribbons 20 can be produced. If a protective resin sheet 15 is attached to the top layer, the laminated substrate 300 shown in FIG. 8 can be constructed.

[0046] The laminated substrate 300 of the present disclosure has three or more layers of nanocrystalline alloy ribbons 20. The number of layers is preferably four or more, and more preferably five or more. There is no particular limit to the upper limit of the number of layers. The number of layers may be determined appropriately. 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 shape may be defective when winding the sheet-shaped magnetic member 300. 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, the number of layers is 25 or less, more preferably, the number of layers is 20 or less, more preferably, the number of layers is 15 or less, and more preferably, the number of layers is 10 or less.

[0047] [Panel base] FIG. 6 is a conceptual diagram illustrating the configuration of a panel base according to the present disclosure. 6, the laminated substrate 300 is written as LA. The arrow next to LA indicates the orientation of the nanocrystalline alloy ribbon 20 in the laminated substrate 300. The orientation of the nanocrystalline alloy ribbon 20 is the direction from the free solidification surface of the nanocrystalline alloy ribbon 20 toward the roll contact surface, and the five layers of the nanocrystalline alloy ribbon 20 of the laminated substrate 300 are oriented in the same direction. Note that the orientation of the nanocrystalline alloy ribbon 20 may also be the direction from the roll contact surface of the nanocrystalline alloy ribbon 20 toward the free solidification surface. The arrows on the panel base PB indicate the direction of the nanocrystalline alloy ribbons 20, and the panel base PB is formed by combining laminated bases having the same lamination direction.

[0048] Fig. 6 is a conceptual diagram showing the surface where the short side of the laminated substrate LA (the short side of the magnetic ribbon) is laminated. The panel substrate PB shown in Fig. 6 is formed by arranging a plurality of laminated substrates LA in the short side direction in a plate shape, and further stacking the laminated substrates LA. At this time, the laminated substrate LA is a combination of a plurality of types of laminated substrates LA with different widths. When stacking the laminated bases LA in the stacking direction, the positions of the laminated bases LA are shifted in the short side direction, so that the magnetic gaps generated between adjacent laminated bases LA are not continuous in the stacking direction.

[0049] Fig. 7 is a schematic diagram showing another example of producing a panel base PB. In the example shown in Fig. 7, laminated bases LA1 of the same size are stacked while being shifted in the width direction. At this time, the ends of the laminated bases are not aligned at the ends. After that, the ends can be cut to produce the panel base PB shown in Fig. 6.

[0050] The number of layers of the nanocrystalline alloy ribbons 20 in the panel base PB of the present disclosure is preferably 15 layers or more. More preferably, it is 20 layers or more. There is no particular upper limit on the number of layers. The number of layers may be determined appropriately. For example, it may be a number of layers that is convenient for forming the sheet-like magnetic member. For example, it may be 100 layers, 100 layers or less, or 100 layers or more. In addition, in consideration of the manufacturing labor hours and handling of the panel base, it may be 50 layers or less, and further, it is preferable to set it to 40 layers or less, 30 layers or less, or 25 layers or less.

[0051] The dimensions of the panel base PB can be appropriately set depending on the dimensions of the sheet-shaped magnetic member to be produced by combining the panel base PB. In other words, the dimensions should be set so that the sheet-shaped magnetic member to be used can be easily assembled. For example, a width of about 100 to 500 mm and a length of about 100 to 1000 mm are preferable for ease of handling.

[0052] [Sheet-shaped magnetic member] FIG. 1 is a conceptual diagram showing a sheet-shaped magnetic member according to a first embodiment of the present disclosure. The sheet-shaped magnetic member of the first embodiment is configured by stacking two panel bases PB. The two panel bases PB are stacked with their lamination directions reversed. Here, the arrow of the panel base PB indicates the lamination direction of the panel base PB. Here, the lamination direction is the direction from the free solidification surface of the nanocrystalline alloy ribbon 20 toward the roll contact surface. Alternatively, the lamination direction may be the direction from the roll contact surface toward the free solidification surface.

[0053] When the panel base PB is produced, warping may occur in the panel base PB, particularly at the edges and corners. It is presumed that the warping of the panel base PB is caused by the nanocrystalline alloy ribbon 20. The nanocrystalline alloy ribbon is manufactured by a single roll method in accordance with the fact that it is a very thin ribbon, and warping may occur due to a difference between the roll contact surface and the free solidification surface, heat treatment, etc. In addition, the influence of the support of the adhesive layer provided on one side of the nanocrystalline alloy ribbon and the resin sheet provided on one side of the adhesive layer is considered. These supports and resin sheets are subjected to tension during transportation. Therefore, they are in a slightly stretched state during transportation. Then, after the nanocrystalline alloy ribbon is cracked, the support and resin sheet are likely to warp toward the nanocrystalline alloy ribbon. As a result, warping may occur in the nanocrystalline alloy ribbon and its laminate. Even if the warping is slight in one nanocrystalline alloy ribbon, it may become a warping that cannot be ignored by stacking multiple layers, for example, 100 layers. For example, if a warped panel base is used, unevenness will occur in the sheet-shaped magnetic member. If projections and recesses are formed on the sheet-shaped magnetic member, the flatness of the sheet-shaped magnetic member is impaired.

[0054] Therefore, when stacking the panel bases PB, by stacking the panel bases PB with the lamination direction reversed, it is possible to cancel out the warping and reduce unevenness of the sheet-shaped magnetic members due to the warping. Therefore, the lamination direction of the panel base PB can be regarded as the warping direction of the panel base PB.

[0055] FIG. 2 is a conceptual diagram showing a sheet-shaped magnetic member according to the second embodiment of the present disclosure. The sheet-shaped magnetic member of the second embodiment is configured by combining four panel bases PB. Two panel bases PB are arranged side by side, and two more panel bases PB are stacked on top of them. The upper and lower panel bases PB are stacked with their stacking directions reversed.

[0056] FIG. 3 is a conceptual diagram showing a sheet-shaped magnetic member according to the third embodiment of the present disclosure. The sheet-shaped magnetic member of the third embodiment is constructed by combining 12 panel bases PB. Three panel bases PB are arranged, and three panel bases PB are stacked on top of them to form four layers. The upper and lower panel bases PB are stacked with their stacking directions reversed. The upper and lower panel bases PB are stacked with their positions shifted from each other in the short side direction. This makes it possible to configure the magnetic gaps generated between adjacent panel bases PB not to be continuous in the stacking direction. For this reason, panel bases PB with different width dimensions are combined.

[0057] Fig. 4 is a conceptual diagram showing another configuration for producing the sheet-shaped magnetic member of the third embodiment of the present disclosure. In the configuration shown in Fig. 4, the sheet-shaped magnetic member of the third embodiment shown in Fig. 3 can also be produced by using panel bases PB of the same width, stacking the upper and lower panel bases PB with their positions shifted in the width direction, and cutting off the portions protruding in the width direction.

[0058] FIG. 5 is a conceptual diagram showing a sheet-shaped magnetic member according to the fourth embodiment of the present disclosure. The sheet-like magnetic member of the fourth embodiment is constructed by combining 12 panel bases PB. Three panel bases PB are arranged, and three panel bases PB are stacked on top of them to form four layers. The upper and lower panel bases PB are stacked with their stacking directions reversed. The upper and lower panel bases PB are stacked with their positions shifted from each other in the short side direction. At this time, the deviation dimension of the panel bases PB is reduced, and the deviation at the ends is reduced. The deviation at the ends can also be used as it is. This results in a configuration in which the magnetic gaps generated between adjacent panel bases PB are not continuous in the stacking direction. In this case, the misalignment dimension in the width direction of the panel base PB is preferably 0.5 mm or more. It is also preferable that it is 1 mm or more, and more preferably 3 mm or more. There is no particular upper limit for the misalignment dimension in the width direction of the panel base PB, but if it is 10 mm or less, the misalignment width at the end portion is not noticeable when the panel base PB is used as is. It is also preferably 5 mm or less.

[0059] In the above, the stacking direction of the panel base PB has been described as the direction of the nanocrystalline alloy ribbons 20, but it may also be configured so that the stacking direction is not the direction of the nanocrystalline alloy ribbons 20, but the direction is the warping direction of the panel base PB when the panel base PB is manufactured, and the panel base PB is inverted and stacked to absorb the warping.

[0060] The sheet-shaped magnetic member of the present disclosure can be produced by combining panel bases PB according to the required thickness and area. When combining the panel bases PB, the panel bases PB are stacked in the inverted lamination direction, thereby suppressing unevenness of the sheet-shaped magnetic member caused by warping of the panel bases PB. According to the present disclosure, a sheet-shaped magnetic member having a large thickness and area can be easily produced and warping can be suppressed. For example, this structure is useful for applications requiring a sheet-shaped magnetic member having a large thickness and area, such as automotive applications.

[0061] The sheet-like magnetic member of the present disclosure may have a resin sheet, another magnetic material, a metal foil such as aluminum, a resin sheet, or the like attached to the bottom or top layer.

[0062] 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. The width may be 50 mm. For example, the width is preferably 15 mm to 100 mm.

[0063] [Manufacturing a sheet material with one layer of nanocrystalline alloy ribbon] The nanocrystalline alloy ribbon was unwound from the roll body around which the nanocrystalline alloy ribbon was wound, an adhesive layer was attached to one side of the nanocrystalline alloy ribbon, and then a cracking roll was directly applied to the side of the nanocrystalline alloy ribbon to which the adhesive layer was not attached, to form cracks in the nanocrystalline alloy ribbon. This state is as shown in FIG. 9. Then, the sheet material was wound into a roll shape. Here, an adhesive layer was attached to the roll contact surface of the nanocrystalline alloy ribbon, and a cracking roll was pressed against the free solidification surface of the nanocrystalline alloy ribbon. In view of the ease of crack formation, the surface against which the cracking roll is pressed is preferably the free solidification surface.

[0064] [Production of Laminated Substrate] Five pieces of the sheet material 100 were used to prepare a laminated substrate having five layers of the nanocrystalline alloy ribbons 20 . Here, five roll-shaped sheet materials 100 were prepared, and each roll-shaped sheet material 100 was unwound and stacked. At this time, the orientation of the free solidification surface and the roll contact surface of the nanocrystalline alloy ribbon was the same in the five layers of magnetic ribbon. In addition, the production of the sheet material and the production of the laminated substrate can be carried out by, for example, the method described in JP-A-2023-144882.

[0065] As described above, a long laminated substrate was produced. The long laminated substrate was cut to produce the required number of laminated substrates as follows. The first laminated substrate LA1 had a width of 30 mm and a length of 120 mm. The second laminated substrate LA2 had a width of 15 mm and a length of 120 mm. The second laminated substrate LA2 was produced by cutting the first laminated substrate LA1. Here, the dimensions of the laminated substrate are the dimensions of the nanocrystalline alloy ribbon. Note that this laminate has five layers of nanocrystalline alloy ribbons.

[0066] [Panel base] A plan view of the produced panel base PB1 is shown in Fig. 10, and a side view is shown in Fig. 11. Eighteen laminated bases LA1 and four laminated bases LA2 were used, and the laminated bases were lined up and stacked as shown in Fig. 11. Specifically, a base material was prepared, the first layer of laminated substrates were arranged and attached to the base material, the second layer of laminated substrates were arranged and attached on top of that, and the third, fourth, and fifth layers were then attached in the same manner to produce the product. The panel substrate PB1 has a width of 120 mm and a length of 120 mm, and is made of 25 layers of nanocrystalline alloy ribbons. In addition, using the same laminated substrates LA1 and LA2, 23 laminated substrates LA1 and 4 laminated substrates LA2 were used, and similarly to the panel substrate PB1, 5 laminated substrates LA1 were arranged in the first layer, and 4 laminated substrates LA1 and 2 laminated substrates LA2 were arranged in the second layer to produce a panel substrate PB2 with a total of 5 layers. This panel substrate PB2 is 150 mm wide and 120 mm long. This panel substrate PB1 also has 25 layers of nanocrystalline alloy ribbons.

[0067] [Production of Sheet-shaped Magnetic Member] Four panel substrates PB1 were stacked, and the stacking direction of the panel substrates was reversed. Four layers of the panel substrate PB1 were fabricated as a panel substrate PB11. Four layers of the panel substrate PB2 were stacked, and the stacking direction of the panel substrates was reversed. Four layers of the panel substrate PB2 were fabricated as a panel substrate PB21. The panel substrates PB11 and PB21 were then arranged side by side, and the long side direction was changed to fabricate the sheet-like magnetic member shown in FIG. 12. The sheet-like magnetic member was 840 mm×390 mm, and had 100 layers of nanocrystalline alloy ribbons. The bottom and top layers of the sheet-like magnetic member were provided with resin sheets. Here, 14 panel substrates PB11 and 7 panel substrates PB21 were combined. In this sheet magnetic member, warping was suppressed in appearance. Also, a plurality of panel bases having different dimensions may be prepared and then assembled to produce the panel.

[0068] According to the sheet-shaped magnetic member of the present disclosure, a laminated substrate is produced, a panel substrate is produced based on the laminated substrate, and the panel substrates are combined to produce the sheet-shaped magnetic member, so that a magnetic sheet having a large thickness and area can be freely produced, and warping can be suppressed.

Claims

1. The magnetic recording medium has a plurality of laminated substrates each having three or more layers of magnetic ribbons formed in a band shape having a short side and a long side, The laminated bases are arranged in a plate shape in a direction in which the short sides extend, with the long sides being adjacent to each other, and the laminated bases are stacked in the stacking direction to form a panel base. a sheet-like magnetic member in which a plurality of the panel bases are stacked and arranged, The panel base is formed by laminating 15 or more layers of the magnetic ribbons, The sheet-shaped magnetic member is formed by laminating 40 or more layers of the magnetic ribbons, A sheet-shaped magnetic member comprising a first panel base and a second panel base stacked on the first panel base, wherein the stacking orientation of the first panel base and the stacking orientation of the second panel base are reversed.

2. 2. The sheet-shaped magnetic member according to claim 1, wherein the lamination direction of the first panel base and the lamination direction of the second panel base correspond to the warping direction of the panel base.

3. 2. The sheet-shaped magnetic member according to claim 1, wherein the lamination direction of the first panel base and the lamination direction of the second panel base are the directions of the free solidification surface and the roll contact surface of the magnetic ribbon.

4. the magnetic ribbon is a nanocrystalline alloy ribbon, The sheet-shaped magnetic member according to claim 1 , wherein the nanocrystalline alloy ribbon is divided into a plurality of small pieces.

5. The sheet-shaped magnetic member according to claim 1 , wherein the panel bases are arranged in a plate shape.

6. The sheet-shaped magnetic member according to claim 1, wherein a support formed in a band shape and an adhesive layer having an adhesive provided on a first surface and a second surface of the support are provided between adjacent magnetic ribbons in the laminated base.

7. The sheet-shaped magnetic member according to claim 1, wherein in the direction in which the laminated substrates are stacked, a band-shaped support and two layers of adhesive layers having an adhesive provided on a first surface and a second surface of the support are arranged between adjacent laminated substrates.

8. A sheet-shaped magnetic member as described in claim 1, wherein in the direction in which the panel bases are stacked, a band-shaped support and two layers of adhesive layers having an adhesive provided on first and second surfaces of the support are arranged between adjacent panel bases.

9. 2. The sheet-shaped magnetic member according to claim 1, wherein a resin sheet is provided as an uppermost layer and a lowermost layer of the sheet-shaped magnetic member.

10. A laminated substrate is formed by stacking three or more magnetic ribbons formed in a band shape having short sides and long sides, A plurality of the laminated bases are arranged in a plate shape in a direction in which the short sides extend, with the long sides being adjacent to each other, and a plurality of the laminated bases are stacked in a stacking direction to form a panel base; A manufacturing method of a sheet-shaped magnetic member comprising stacking a plurality of the panel bases to form a sheet-shaped magnetic member, comprising the steps of: The panel base is formed by laminating 15 or more layers of the magnetic ribbons, The sheet-shaped magnetic member is formed by laminating 40 or more layers of the magnetic ribbons, A method for manufacturing a sheet-shaped magnetic member, in which when a second panel base is stacked on a first panel base, the stacking directions of the first panel base and the second panel base are reversed.

11. The method for manufacturing a sheet-shaped magnetic member according to claim 10 , wherein a lamination direction of the first panel base and a lamination direction of the second panel base correspond to a warping direction of the panel base.

12. The method for manufacturing a sheet-shaped magnetic member according to claim 10, wherein the stacking direction of the first panel base and the stacking direction of the second panel base are the directions of the free solidification surface and the roll contact surface of the magnetic ribbon.

13. the magnetic ribbon is a nanocrystalline alloy ribbon, The method for producing a sheet-shaped magnetic member according to claim 10, wherein the nanocrystalline alloy ribbon is divided into a plurality of small pieces.

14. The method for producing a sheet-shaped magnetic member according to claim 10, wherein a plurality of the panel bases are arranged side by side in a plate shape.

Images