Method for manufacturing magnetic sheets and apparatus for manufacturing magnetic sheets

Abstract

To provide a manufacturing method of a magnetic sheet in which a nano crystal alloy ribbon having a crack and a pressure-sensitive adhesive sheet are laminated, the manufacturing method enabling the suppression of fracture of the nano crystal alloy ribbon when the magnetic sheet is manufactured.SOLUTION: A manufacturing method of a magnetic sheet is provided, including: an amorphous alloy ribbon transportation step of continuously transporting an amorphous alloy ribbon; a heat treatment step of performing heat treatment of the amorphous alloy ribbon by bringing the amorphous alloy ribbon into contact with a heating body, thereby obtaining a nano crystal alloy ribbon; a nano crystal alloy ribbon transportation step of continuously transporting the nano crystal alloy ribbon; a step of obtaining a laminate by bonding the nano crystal alloy ribbon with a pressure-sensitive adhesive sheet; and a crack formation step of forming a crack in the nano crystal alloy ribbon of the laminate by bringing the laminate into contact with a crack roll, thereby obtaining the magnetic sheet. In the manufacturing method of the magnetic sheet, the amorphous alloy ribbon transportation step, the heat treatment step, the nano crystal alloy ribbon transportation step, the adhesion step, and the crack formation step are sequentially performed in this order.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This disclosure relates to a method for manufacturing a magnetic sheet and an apparatus for manufacturing a magnetic sheet. [Background technology]

[0002] In recent years, technologies related to nanocrystalline alloy strips with resin films, which can be used as magnetic sheets, have been investigated.

[0003] For example, paragraphs 0028 to 0038 and Figure 1 of Patent Document 1 disclose an in-line annealing apparatus that unwinds an amorphous alloy strip from a wound body of amorphous alloy strips using an unwinding roll, applies a heat treatment including heating and cooling to the unwinded amorphous alloy strip to obtain a nanocrystalline alloy strip, and winds the obtained nanocrystalline alloy strip using a winding roll to obtain a roll of nanocrystalline alloy strips. Paragraph 0039 and Figure 2 of this Patent Document 1 disclose an example of a lamination process in which a nanocrystalline alloy strip, an adhesive layer, and a resin film are unwound from a winding of a nanocrystalline alloy strip, an adhesive layer, and a resin film, respectively, and the unwound nanocrystalline alloy strip, adhesive layer, and resin film are laminated and integrated using a pair of pressure rolls to obtain a nanocrystalline alloy strip with a resin film. Paragraphs 0043 to 0051 of Patent Document 1 disclose an example of forming cracks in a nanocrystalline alloy strip with a resin film using a crack roll or the like. Furthermore, it is disclosed that forming cracks in a nanocrystalline alloy strip with a resin film and dividing the nanocrystalline alloy strip into multiple pieces can reduce eddy currents (see paragraph 0044 of Patent Document 1). [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] International Publication No. 2020 / 235643 [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] Incidentally, in some cases, magnetic sheets are used in which a thin strip of nanocrystalline alloy containing cracks and an adhesive sheet are laminated together. If this magnetic sheet were to be manufactured using conventional technology (for example, the technology described in Patent Document 1 above; the same applies hereinafter), it would be necessary to first wind up a nanocrystalline alloy strip, which is produced by heat treatment of an amorphous alloy strip, into a coil, then unwind the nanocrystalline alloy strip from this coil, and then bond the unwinded nanocrystalline alloy strip with an adhesive sheet and form cracks. However, when the above-mentioned magnetic sheet is manufactured using the above-mentioned conventional technology, fracture of the nanocrystalline alloy strip may occur during winding and / or unwinding of the nanocrystalline alloy strip before bonding the nanocrystalline alloy strip to the adhesive sheet, due to the brittleness characteristic of the nanocrystalline alloy strip.

[0006] The object of this disclosure is to provide a method for manufacturing a magnetic sheet and an apparatus for manufacturing a magnetic sheet that can suppress the fracture of the nanocrystalline alloy strip when manufacturing a magnetic sheet in which a nanocrystalline alloy strip having cracks and an adhesive sheet are laminated. [Means for solving the problem]

[0007] The following embodiments are included as specific means to solve the above problems. <1> An amorphous alloy thin strip conveying process in which an amorphous alloy thin strip is continuously conveyed under tension, A heat treatment step to obtain a nanocrystalline alloy strip by heat-treating the amorphous alloy strip by bringing it into contact with a heated body while tension is applied, A nanocrystalline alloy thin strip transport process in which the nanocrystalline alloy thin strip is continuously transported while tension is applied, A bonding step to obtain a laminate by bonding the nanocrystalline alloy thin strip and the adhesive sheet while tension is applied, A crack formation step is performed to form cracks in the nanocrystalline alloy strip of the laminate by bringing it into contact with a crack roll in order to obtain a magnetic sheet. Includes, The amorphous alloy thin strip transport step, the heat treatment step, the nanocrystalline alloy thin strip transport step, the bonding step, and the crack formation step are carried out in succession in that order. A method for manufacturing magnetic sheets. <2> When the width of the adhesive sheet is denoted as width A and the width of the nanocrystalline alloy strip as width B, the value obtained by subtracting width B from width A is between 0.2 mm and 3.0 mm. <1> A method for manufacturing a magnetic sheet as described above. <3> The bonding step includes adjusting the positions of both end faces in the width direction of the nanocrystalline alloy strip before bonding the nanocrystalline alloy strip and the adhesive sheet. <1> or <2> A method for manufacturing a magnetic sheet as described above. <4> The nanocrystalline alloy thin strip transport process includes adjusting the tension of the nanocrystalline alloy thin strip using a tension adjustment device. <1> ~ <3> A method for manufacturing a magnetic sheet as described in any one of the following. <5> The adhesive sheet is made up of an adhesive layer, or is a double-sided adhesive tape including a support and adhesive layers provided on both sides of the support. <1> ~ <4> A method for manufacturing a magnetic sheet as described in any one of the following.

[0008] <6> An amorphous alloy thin strip conveying device that continuously conveys amorphous alloy thin strips while applying tension, A heat treatment apparatus comprising a heating element that comes into contact with the amorphous alloy thin strip under tension, the amorphous alloy thin strip being heat-treated to obtain a nanocrystalline alloy thin strip, A nanocrystalline alloy thin strip transport device that continuously transports the nanocrystalline alloy thin strip while tension is applied, A bonding apparatus for bonding the nanocrystalline alloy thin strip and an adhesive sheet together while tension is applied to obtain a laminate, comprising a crack roll contacting the nanocrystalline alloy ribbon of the laminate, a crack forming apparatus that forms cracks in the nanocrystalline alloy ribbon of the laminate to obtain a magnetic sheet, and comprising an apparatus for manufacturing a magnetic sheet. <7> further comprising, between the heat treatment apparatus and the laminating apparatus, a ribbon end surface position adjusting apparatus that adjusts the positions of both end surfaces in the width direction of the nanocrystalline alloy ribbon, the apparatus for manufacturing a magnetic sheet according to <6>. <8> further comprising, between the heat treatment apparatus and the laminating apparatus, a tension adjusting apparatus that adjusts the tension of the nanocrystalline alloy ribbon, the apparatus for manufacturing a magnetic sheet according to <6> or <7>. Advantageous Effects of the Invention

[0009] According to the present disclosure, when manufacturing a magnetic sheet in which a cracked nanocrystalline alloy ribbon and an adhesive sheet are laminated, a method for manufacturing a magnetic sheet and an apparatus for manufacturing a magnetic sheet that can suppress breaking of the nanocrystalline alloy ribbon are provided. Brief Description of Drawings

[0010] [Figure 1] FIG. 1 is a schematic cross-sectional view showing an example of a magnetic sheet manufacturing apparatus for carrying out the magnetic sheet manufacturing method of the present disclosure. [Figure 2] FIG. 2 is a schematic cross-sectional view showing in detail the heat treatment apparatus in the example shown in FIG. 1. [Figure 3] FIG. 3 is a diagram showing in detail the rear half portion including the bonding roll and the crack roll in the example shown in FIG. 1. [Figure 4] FIG. 4 is a schematic cross-sectional view showing an example of an adhesive sheet with a double-sided release liner according to the present disclosure. [Figure 5] FIG. 5 is a schematic cross-sectional view showing an example of an adhesive sheet with a single-sided release liner according to the present disclosure. [Figure 6] FIG. 6 is a schematic cross-sectional view showing an example of a nanocrystalline alloy ribbon according to the present disclosure. [Figure 7]This is a schematic cross-sectional view showing an example of a laminate obtained in the bonding process described herein. [Figure 8] This is a schematic cross-sectional view showing an example of a magnetic sheet in this disclosure. [Figure 9] This is a schematic cross-sectional view showing another example of an adhesive sheet with a single-sided peel-off liner in this disclosure. [Figure 10] This is a schematic cross-sectional view showing another example of an adhesive sheet with a double-sided peel-off liner in this disclosure. [Figure 11] This is a schematic cross-sectional view showing another example of a magnetic sheet in this disclosure. [Figure 12] This is a schematic cross-sectional view showing a modified example of the heat treatment apparatus in this disclosure. [Modes for carrying out the invention]

[0011] In this disclosure, a numerical range represented by "~" means a range that includes the numbers written before and after "~" as the lower and upper limits, respectively. In this disclosure, the term "process" includes not only independent processes but also any process that cannot be clearly distinguished from other processes, as long as its intended purpose is achieved. In this disclosure, terms such as "first," "second," and "third" are merely for identification purposes and do not imply order, priority, or anything of the sort.

[0012] In this disclosure, the term "Fe-based amorphous alloy thin strip" refers to a thin strip made of an Fe-based amorphous alloy. In this disclosure, Fe-based amorphous alloy refers to an amorphous alloy whose main component is Fe (iron). Here, the main component refers to the component with the highest content ratio (mass%). In this disclosure, "nanocrystalline alloy" means an alloy having an alloy structure containing nanocrystalline grains. The concept of "nanocrystalline alloy" also includes alloys having an alloy structure containing nanocrystalline grains and an amorphous phase. Here, the nanocrystalline grains are crystalline grains with a particle size of 1 nm or more and 100 nm or less, preferably crystalline grains with a particle size of 10 nm or more and 50 nm or less.

[0013] [Method for manufacturing magnetic sheets] The method for manufacturing a magnetic sheet as disclosed herein (hereinafter also referred to as the "method of manufacturing as disclosed herein") is: An amorphous alloy thin strip conveying process in which an amorphous alloy thin strip is continuously conveyed under tension, A heat treatment process to obtain a nanocrystalline alloy strip by heat-treating an amorphous alloy strip by bringing it into contact with a heated body while tension is applied, A nanocrystalline alloy thin strip transport process in which a nanocrystalline alloy thin strip is continuously transported under tension, A bonding process to obtain a laminate by bonding a nanocrystalline alloy strip and an adhesive sheet while tension is applied, A crack formation process is performed to form cracks in a nanocrystalline alloy strip of a laminate by bringing it into contact with a crack roll, thereby obtaining a magnetic sheet. Includes, The process is carried out sequentially in the following order: amorphous alloy thin strip transport process, heat treatment process, nanocrystalline alloy thin strip transport process, bonding process, and crack formation process. This is a method for manufacturing magnetic sheets. The manufacturing method disclosed herein may include other steps as necessary.

[0014] In the manufacturing method of the present disclosure, as described above, the amorphous alloy strip transport step, heat treatment step, nanocrystalline alloy strip transport step, bonding step, and crack formation step are performed sequentially in this order. In the manufacturing method of the present invention, the above operations are carried out consistently without the need for winding and unwinding operations. Therefore, the manufacturing method of this disclosure makes it possible to reduce the number of winding and unwinding operations in the process of obtaining a magnetic sheet from an amorphous alloy thin strip. Therefore, according to the manufacturing method of the present disclosure, when manufacturing a magnetic sheet, it is possible to suppress the fracture of the nanocrystalline alloy strip, which is caused by the embrittlement characteristics unique to the nanocrystalline alloy strip.

[0015] In contrast to the manufacturing method disclosed herein, when the magnetic sheet is manufactured by the manufacturing method described in Patent Document 1 (International Publication No. 2020 / 235643), a winding operation is required in which the nanocrystalline alloy strip, manufactured by heat-treating an amorphous alloy strip, is first wound up. Furthermore, the wound nanocrystalline alloy strip must be unwound again to bond it with the adhesive sheet and to form cracks. For this reason, during the winding and / or unwinding of the nanocrystalline alloy strip, fracture of the nanocrystalline alloy strip may occur due to the brittleness characteristics unique to the nanocrystalline alloy strip. In contrast, the manufacturing method of the present disclosure eliminates the winding and unwinding operations of the nanocrystalline alloy strip, thereby suppressing the breakage of the nanocrystalline alloy strip.

[0016] An example of the manufacturing method described herein will be explained below with reference to the drawings, but the manufacturing method described herein is not limited to the following example. In the following, components having substantially the same function will be assigned the same reference numeral throughout all drawings, and their descriptions may be omitted. Furthermore, the dimensional ratios in the drawings may be exaggerated for illustrative purposes and may differ from the actual ratios.

[0017] Figure 1 is a schematic cross-sectional view showing a magnetic sheet manufacturing apparatus 100, which is an example of a magnetic sheet manufacturing apparatus for carrying out the magnetic sheet manufacturing method of this disclosure. Figure 2 is a detailed view of the heat treatment apparatus in one example shown in Figure 1. Figure 3 is a detailed view of the latter half of the example shown in Figure 1, including the bonded roll and the crack roll.

[0018] The magnetic sheet manufacturing apparatus 100 is also an example of the magnetic sheet manufacturing apparatus described herein, which will be discussed later.

[0019] As shown in Figures 1 to 3, in the manufacturing of magnetic sheets using the magnetic sheet manufacturing apparatus 100, An amorphous alloy thin strip 10A is unwound from a coil 10, which is made up of a long amorphous alloy thin strip 10A wound around it. The unwound amorphous alloy thin strip 10A is continuously transported. A nanocrystalline alloy strip 10B is manufactured by heat-treating (i.e., heating and cooling) the continuously transported amorphous alloy strip 10A in the heat treatment apparatus 30. The manufactured nanocrystalline alloy thin strip 10B is continuously transported without being wound up. A laminate 70A is manufactured by bonding a continuously transported nanocrystalline alloy thin strip 10B and an adhesive sheet 60A with a single-sided peel-off liner. A magnetic sheet 70B is manufactured by applying pressure to the nanocrystalline alloy strip 10B in the manufactured laminate 70A with a crack roll 72 to form cracks. The obtained magnetic sheet 70B is wound up by the winding device 81.

[0020] As shown in Figure 5, the adhesive sheet 60A with a single-sided release liner includes a release liner 60Ab and an adhesive layer 60Aa as an adhesive sheet. As shown in Figure 7, the laminate 70A is a laminate obtained by bonding a nanocrystalline alloy strip 10B and an adhesive sheet 60A with a single-sided release liner in a configuration in which the nanocrystalline alloy strip 10B and the adhesive layer 60Aa acting as the adhesive sheet are in contact. As shown in Figure 8, the magnetic sheet 70B is a magnetic sheet comprising a nanocrystalline alloy strip 10BA having cracks 10BB and an adhesive sheet 60A with a single-sided release liner, which includes a release liner 60Ab and an adhesive layer 60Aa, arranged so that the nanocrystalline alloy strip 10BA having cracks and the adhesive layer 60Aa are in contact with each other. As shown in Figures 7 and 8, the magnetic sheet 70B is formed by cracks being formed in the nanocrystalline alloy strip 10B in the laminate 70A. That is, the nanocrystalline alloy strip 10BA having crack 10BB in the magnetic sheet 70B is formed by cracks being formed in the nanocrystalline alloy strip 10B.

[0021] As described above, the magnetic sheet manufacturing apparatus 100 is an in-line type manufacturing apparatus that continuously transports the amorphous alloy strip 10A, which is the starting material, the nanocrystalline alloy strip 10B, which is the intermediate material, and the magnetic sheet 70B, which is the target product, using an in-line continuous transport method.

[0022] The structure of the magnetic sheet manufacturing apparatus 100 will be described in more detail below. In the following explanation, "upstream" and "downstream" refer to the upstream and downstream sides, respectively, with respect to the transport direction of the thin strip (i.e., amorphous alloy thin strip or nanocrystalline alloy thin strip) or laminate.

[0023] As shown in Figure 1, the magnetic sheet manufacturing apparatus 100 includes an unwinding device 11 (for example, an unwinding roll) that unwinds the amorphous alloy strip 10A from a coil 10 in which a long amorphous alloy strip 10A is wound. As the amorphous alloy strip 10A, for example, an Fe-based amorphous alloy strip manufactured by the single-roll method can be used. For the production of Fe-based amorphous alloy thin strips by the single-roll method, publicly available documents such as International Publication No. 2013 / 137118 can be consulted as appropriate. In the single-roll method, Fe-based amorphous alloy strips are typically manufactured in the form of a coil, which is a long strip of Fe-based amorphous alloy wound into a coil. The manufactured coil can be used as coil 10, which is the starting material in this example.

[0024] As shown in Figure 1, the magnetic sheet manufacturing apparatus 100 includes an amorphous alloy strip conveying device that continuously conveys the unwound amorphous alloy strip 10A while applying tension. The amorphous alloy thin strip conveying device in the magnetic sheet manufacturing apparatus 100 includes conveying rolls 12 to 15. In the magnetic sheet manufacturing apparatus 100, for example, devices or components located on the conveying path of the amorphous alloy thin strip 10A, such as tension adjustment devices (dancer roll 20 and bridle roll unit 21) and thin strip end face position adjustment devices 25, may also function as amorphous alloy thin strip conveying devices.

[0025] The magnetic sheet manufacturing apparatus 100 is equipped with a dancer roll 20 and a bridle roll unit 21 as tension adjustment devices in the middle of the conveying path of the amorphous alloy thin strip 10A. The bridle roll unit 21 includes bridle rolls 21A, 21B, and 21C. In the magnetic sheet manufacturing apparatus 100, the tension adjustment device makes it easy to adjust the tension of the amorphous alloy strip 10A in the heat treatment apparatus 30 to a tension suitable for the heat treatment conditions required to obtain the nanocrystalline alloy strip 10B by heat treatment of the amorphous alloy strip 10A. The magnetic sheet manufacturing apparatus 100 is further equipped with a tension detection device 24 for detecting the tension of the amorphous alloy thin strip 10A.

[0026] However, tension adjustment devices and tension detection devices for amorphous alloy strips are not essential elements in the magnetic sheet manufacturing apparatus of this disclosure. For example, even if the tension adjustment devices and tension detection devices are omitted, it is possible to continuously transport the amorphous alloy strip 10A under tension and heat-treat it to obtain a nanocrystalline alloy strip 10B.

[0027] In the magnetic sheet manufacturing apparatus 100, a thin sheet end face position adjustment device 25 is provided in the middle of the transport path of the amorphous alloy thin sheet 10A, and further, thin sheet end face detection devices 22 and 23 are provided. In the magnetic sheet manufacturing apparatus 100, the positions of both ends of the amorphous alloy thin sheet 10A in the width direction can be adjusted by these thin sheet end face position adjustment devices and thin sheet end face detection devices. These thin strip end face positioning devices 25 and thin strip end face detection devices 22 and 23 are not essential elements of the magnetic sheet manufacturing apparatus of this disclosure.

[0028] As shown in Figure 1, the magnetic sheet manufacturing apparatus 100 includes a heat treatment apparatus 30 for heat-treating a continuously transported amorphous alloy strip 10A to produce a nanocrystalline alloy strip 10B. In the magnetic sheet manufacturing apparatus 100, an amorphous alloy strip 10A placed in the heat treatment apparatus 30 is heat-treated in the heat treatment apparatus 30 to produce a nanocrystalline alloy strip 10B, and the nanocrystalline alloy strip 10B is then discharged from the heat treatment apparatus 30.

[0029] Figure 2 is a conceptually enlarged partial view showing the details of the heat treatment apparatus 30. The heat treatment apparatus 30 includes, in order from the upstream side in the conveying direction of the thin strip, a pair of guide rolls 31, a heating device 33 containing a heating element 32 inside, a pair of guide rolls 34, a pair of guide rolls 35, a cooling device 37 containing a cooling element 36 inside, and a pair of guide rolls 38. The pair of guide rolls has the function of transporting a thin strip of material by placing it between the pair of guide rolls.

[0030] Both the heating element 32 and the cooling element 36 are metal plate-shaped components. The amorphous alloy thin strip 10A is heated when the upper surface of the heating element 32 comes into contact with the amorphous alloy thin strip 10A. The amorphous alloy thin strip 10A is cooled when the upper surface of the cooling body 36 comes into contact with the amorphous alloy thin strip 10A.

[0031] The amorphous alloy strip 10A, once inside the heating device 33 of the heat treatment apparatus 30, travels while in contact with the upper surface of the heating element 32 located inside the heating device 33 (i.e., it is continuously transported). The amorphous alloy strip 10A is heated by this contact with the upper surface of the heating element 32. The heated amorphous alloy strip 10A is transported by a pair of guide rolls 34 and a pair of guide rolls 35 into the cooling device 37, and moves along the cooling device 37 while in contact with a portion of the cooling body 36 located inside the cooling device 37 (i.e., it is transported continuously). The heated amorphous alloy strip 10A is cooled to, for example, near room temperature by contact with the upper surface of the cooling body 36. The amorphous alloy strip 10A placed in the heat treatment apparatus 30 is heat-treated by the heating and cooling described above. During the heating process, or during the heating and cooling process, nanocrystalline grains are generated within the structure of the amorphous alloy strip 10A, and a nanocrystalline alloy strip 10B is produced (i.e., the amorphous alloy strip 10A is converted into a nanocrystalline alloy strip 10B).

[0032] The temperature of the heating element 32 should be such that the amorphous alloy strip 10A is heated to a temperature at which the nanocrystalline alloy strip 10B is obtained, and can be set appropriately considering the composition of the amorphous alloy strip, etc. Preferred embodiments and variations of the heating element 32, as well as preferred temperatures for the heating element, will be described later.

[0033] The temperature of the heating element 32 should be such that the amorphous alloy strip 10A is heated to a temperature at which the nanocrystalline alloy strip 10B is obtained, and can be set appropriately considering the composition of the amorphous alloy strip, etc. Preferred embodiments and variations of the heating element 32, as well as preferred temperatures for the heating element, will be described later.

[0034] The cooling body 36 may have a cooling mechanism (e.g., a water cooling mechanism), or it may not have any special cooling mechanism (for example, it may be a naturally dissipating cooling body). Preferred embodiments and variations of the cooling body 36 will be described later. Furthermore, the amorphous alloy thin strip 10A may be cooled by air cooling instead of using the cooling body 36. In other words, the cooling body 36 is not an essential element in the magnetic sheet manufacturing apparatus of this disclosure.

[0035] As shown in Figure 1, the magnetic sheet manufacturing apparatus 100 includes a nanocrystalline alloy strip conveying apparatus that continuously conveys the nanocrystalline alloy strip 10B obtained in the heat treatment apparatus 30 under tension without winding it up. The nanocrystalline alloy thin strip conveying device in the magnetic sheet manufacturing apparatus 100 specifically includes conveying rolls 41 to 46. Furthermore, in the magnetic sheet manufacturing apparatus 100, devices or components located on the transport path of the nanocrystalline alloy thin strip 10B, such as tension adjustment devices (bridle roll unit 40 and dancer roll 51) and thin strip end face position adjustment devices 50 and 54, may also function as nanocrystalline alloy thin strip transport devices.

[0036] In the magnetic sheet manufacturing apparatus 100, a bridle roll unit 40 and a dancer roll 51 are provided as tension adjustment devices in the middle of the transport path of the nanocrystalline alloy thin strip 10B, and a thin strip end face position detection device 52 is also provided. The bridle roll unit 40 includes bridle rolls 40A, 40B, and 40C. In the magnetic sheet manufacturing apparatus 100, the tension adjustment device makes it easy to adjust the tension of the nanocrystalline alloy strip 10B immediately after it leaves the heat treatment apparatus 30 (i.e., the tension suitable for the heat treatment process) to a tension suitable for the next bonding process.

[0037] However, tension adjustment devices and tension detection devices for nanocrystalline alloy strips are not essential elements in the magnetic sheet manufacturing apparatus of this disclosure. For example, even if a tension adjustment detection device for the nanocrystalline alloy strip is omitted, it is still possible to continuously transport the nanocrystalline alloy strip under tension and perform the operation of the next bonding process.

[0038] The magnetic sheet manufacturing apparatus 100 includes a conveying roll 46 as a nanocrystalline alloy thin strip conveying apparatus, a bonding roll 71 (bonding apparatus) for bonding the nanocrystalline alloy thin strip 10B and an adhesive sheet 60A with a single-sided release liner, and between these, a thin strip end face position adjustment apparatus 54 for adjusting the positions of both end faces in the width direction of the nanocrystalline alloy thin strip 10B, and a thin strip end face detection apparatus 55. The magnetic sheet manufacturing apparatus 100, by including a thin strip end face position adjustment device 54, can more effectively suppress misalignment (specifically, misalignment in the width direction of the nanocrystalline alloy thin strip 10B) when bonding the nanocrystalline alloy thin strip 10B and the adhesive sheet 60A with a single-sided release liner. These thin sheet end face positioning devices 54 and thin sheet end face detection devices 55 are not essential elements in the magnetic sheet manufacturing apparatus of this disclosure.

[0039] The magnetic sheet manufacturing apparatus 100 includes a bonding roll 71 as a bonding device that bonds a nanocrystalline alloy strip 10B, which is continuously conveyed under tension, and an adhesive sheet 60A with a single-sided peel-off liner, to obtain a laminate 70A. The bonding roll 71, which functions as a bonding device, consists of a pair of rolls. In the bonding process using the bonding roll 71, the nanocrystalline alloy strip 10B (see Figure 6), which has been transported via a separate route, and the adhesive sheet 60A with a single-sided release liner (see Figure 5) are sandwiched between a pair of rolls forming the bonding roll 71, and bonded in a configuration where the nanocrystalline alloy strip 10B and the adhesive layer 60Aa are in contact. This bonding process yields a laminate 70A (see Figures 3 and 7).

[0040] Here, the adhesive sheet 60A with a single-sided release liner is transported to the lamination roll 71 via a separate route from the nanocrystalline alloy strip 10B. The following describes the supply route from the adhesive sheet 60A with a single-sided release liner to the laminated roll 71. The supply route for the nanocrystalline alloy strip 10B up to the bonding roll 71 has already been explained.

[0041] The adhesive sheet 60A with a single-sided release liner is a long-length member obtained by peeling off one of the release liners, the release liner 60B, from the adhesive sheet 60 with a double-sided release liner, which is a long-length member. Figure 4 is a schematic cross-sectional view showing an adhesive sheet with a double-sided release liner. As shown in Figure 4, the adhesive sheet 60 with a double-sided release liner includes an adhesive sheet 60A with a single-sided release liner and a release liner 60B located on the opposite side from the release liner 60Ab when viewed from the adhesive layer 60Aa of the adhesive sheet 60A.

[0042] As shown in Figures 1 and 3, in this example, a long roll of adhesive sheet 60 with a double-sided release liner is set in an unwinding device 61. Next, the adhesive sheet 60 with a double-sided release liner is unwound from the unwinding device 61, and the release liner 60B is peeled off from the unwound adhesive sheet 60. The adhesive sheet 60A with a single-sided release liner obtained by peeling off the release liner 60B from the adhesive sheet 60 with a double-sided release liner is conveyed to the bonding roll 71 by conveying rolls 63 to 65, which act as a conveying device. The peeled-off peel liner 60B is wound up by the winding device 62.

[0043] In the magnetic sheet manufacturing apparatus 100, the laminated body 70A obtained by the bonding described above is continuously conveyed under tension. This continuous conveyance is achieved by the winding action of the winding device 81, which will be described later.

[0044] The magnetic sheet manufacturing apparatus 100 includes a crack forming apparatus (specifically, a crack roll 72 and a pressing roll 73) for obtaining a magnetic sheet 70B (see Figure 8) by forming cracks in the nanocrystalline alloy strip 10B in the laminate 70A which is continuously conveyed under tension. In detail, crack formation is performed by bringing a crack roll 72 into contact with a nanocrystalline alloy strip 10B in a laminate 70A that is continuously transported under tension, and applying pressure. The crack roll 72 has protrusions on its surface for crack formation. In the crack forming apparatus, a pressing roll 73 is positioned opposite the crack roll 72. In crack formation, the laminate 70A is sandwiched between the crack roll 72 and the pressing roll 73 in a configuration where the nanocrystalline alloy strip 10B and the crack roll 72 are in contact. As a result, the nanocrystalline alloy strip 10B in the laminate 70A is pressed by the surface irregularities of the crack roll 72, and cracks 10BB are formed in the nanocrystalline alloy strip 10B in the laminate 70A. This yields the magnetic sheet 70B (see Figures 3, 7, and 8).

[0045] The magnetic sheet manufacturing apparatus 100 includes a conveying roll 77, a pair of nip rolls 74, a pair of flattening rolls 75, a conveying roll 78, and a winding device 81 for winding up the magnetic sheet 70B, located downstream in the conveying direction of the magnetic sheet 70B. The conveyor roll 77, the pair of nip rolls 74, the pair of flattening rolls 75, and the conveyor roll 78 may be omitted.

[0046] The above describes an example of a manufacturing method according to the present disclosure, through the explanation of the magnetic sheet manufacturing apparatus 100. However, the manufacturing method according to the present disclosure is not limited to the above example. The following describes the magnetic sheet, which is the object of the manufacturing method of this disclosure, and then describes preferred embodiments of each step in the manufacturing method of this disclosure.

[0047] <Magnetic Sheet> The magnetic sheet that is the subject of the manufacturing method of this disclosure is a magnetic sheet in which a nanocrystalline alloy strip having cracks and an adhesive sheet are laminated together. The magnetic sheet may include elements other than the nanocrystalline alloy strip having cracks and the adhesive sheet (e.g., a release liner). For example, the magnetic sheet may include a nanocrystalline alloy strip having cracks and an adhesive sheet with a single-sided peel-off liner.

[0048] An example of a magnetic sheet is the magnetic sheet 70B shown in Figure 8, and an example of an adhesive sheet with a single-sided release liner is the adhesive sheet 60A shown in Figure 5, as described above. The magnetic sheet 70B shown in Figure 8 is a magnetic sheet comprising a nanocrystalline alloy strip 10BA having cracks 10BB, and an adhesive sheet 60A with a single-sided release liner, which includes a release liner 60Ab and an adhesive layer 60Aa as an adhesive sheet, arranged so that the nanocrystalline alloy strip 10BA having cracks and the adhesive layer 60Aa are in contact with each other.

[0049] Magnetic sheets can be used for a variety of purposes. For example, an adhesive sheet in a magnetic sheet can be used to bond the magnetic sheet to other components. Furthermore, by stacking multiple magnetic sheets, it is possible to form a laminated device containing multiple nanocrystalline alloy strips with cracks.

[0050] The presence of cracks in the nanocrystalline alloy strips within the magnetic sheet reduces eddy current losses.

[0051] The preferred size (length, width, and thickness) of the nanocrystalline alloy strip in the magnetic sheet is the same as the preferred size (length, width, and thickness) of the amorphous alloy strip described later.

[0052] The adhesive sheet is preferably made up of an adhesive layer, or is a double-sided adhesive tape that includes a support and adhesive layers provided on both sides of the support.

[0053] The adhesive layer and support that may be included in the adhesive sheet can be those known and used in the field of double-sided adhesive tapes, respectively.

[0054] An example of an adhesive sheet consisting of an adhesive layer is the adhesive layer 60Aa shown in Figures 4, 5, and 8 above. In this embodiment, the adhesive layer may be a single adhesive layer or two or more adhesive layers.

[0055] Figure 9 is a schematic cross-sectional view showing an example of an adhesive sheet with a single-sided release liner, namely an adhesive sheet 160A, where the adhesive sheet is a double-sided adhesive tape comprising a support and adhesive layers provided on both sides of the support. Figure 10 is a schematic cross-sectional view showing an adhesive sheet 160 with a single-sided release liner, 160A, and a double-sided release liner, 60B. Figure 11 is a schematic cross-sectional view showing a magnetic sheet 170B including an adhesive sheet 160A with a single-sided release liner.

[0056] As shown in Figures 9 to 11, the adhesive sheet 160A with a single-sided release liner includes a release liner 160Ab and a double-sided adhesive tape 160Aa as an adhesive sheet. The double-sided adhesive tape 160Aa includes a support 160Aa1 and adhesive layers 160Aa2 provided on both sides of the support 160Aa1. The adhesive sheet 160A with a single-sided release liner shown in Figures 9 to 11 differs from the adhesive sheet 60A with a single-sided release liner shown in Figures 4, 5, and 8, in that the adhesive sheet is a double-sided adhesive tape 160Aa, while the adhesive sheet is a single adhesive layer 60Aa. Aside from this difference, the structure of the adhesive sheet 160A with a single-sided release liner is substantially the same as that of the adhesive sheet 60A with a single-sided release liner.

[0057] In the magnetic sheet described herein, when the width of the adhesive sheet is width A and the width of the nanocrystalline alloy thin strip is width B, the value obtained by subtracting width B from width A (hereinafter also referred to as the difference [width A - width B]) is preferably 0.2 mm to 3.0 mm. When the difference [width A - width B] is 0.2 mm or more, even if the continuously transported nanocrystalline alloy thin strip experiences a displacement in the direction of width B, the adhesive sheet can be easily attached to the entire length of the nanocrystalline alloy thin strip in the direction of width B. When the difference [width A - width B] is 3.0 mm or less, it is easier to secure width B of the nanocrystalline alloy thin band. The lower limit of the difference [width A - width B] is more preferably 0.5 mm, and more preferably 1.0 mm. The upper limit of the difference [width A1 - width B] is 2.5 mm, and more preferably 2.0 mm.

[0058] In the magnetic sheet of this disclosure, if the adhesive sheet is a double-sided adhesive tape including a support and adhesive layers provided on both sides of the support, and the width of the support is width A1 and the width of the nanocrystalline alloy thin strip is width B, the value obtained by subtracting width B from width A1 (hereinafter also referred to as the difference [width A1 - width B]) is preferably 0.2 mm to 3.0 mm. When the difference [width A1 - width B] is 0.2 mm or more, even if the continuously transported nanocrystalline alloy thin strip experiences a displacement in the direction of width B, the adhesive sheet can be easily attached to the entire length of the nanocrystalline alloy thin strip in the direction of width B. When the difference [width A1 - width B] is 3.0 mm or less, it is easier to secure the width B of the nanocrystalline alloy thin band. Furthermore, when the difference [width A1 - width B] is 3.0 mm or less, it is possible to suppress the excessive spacing between nanocrystalline alloy strips when magnetic sheets are arranged side by side in the width direction. This has the advantage of making it easier to obtain the required properties when used as a magnetic yoke or magnetic shield. The lower limit of the difference [width A1 - width B] is more preferably 0.5 mm, and more preferably 1.0 mm. The upper limit of the difference [width A1 - width B] is more preferably 2.5 mm, and more preferably 2.0 mm.

[0059] <Preparation process> The manufacturing method of the present disclosure may include a preparation step of preparing a coil in which a long amorphous alloy strip is wound. The preparation step may be a process for manufacturing the coil, or it may simply be a process for preparing the coil that has been manufactured in advance. As mentioned above, when amorphous alloy strips are manufactured by the single-roll method, they are usually produced in the form of the coil described above.

[0060] The amorphous alloy strip can be long in length, and there are no particular restrictions on its size (length, width, and thickness).

[0061] The length of the amorphous alloy strip may be 500m or more, 1,000m or more, 4,000m or more, or 10,000m or more. There is no particular upper limit on the length of amorphous alloy ribbons, but the upper limit is, for example, 30,000 m. The length of the amorphous alloy ribbon may be 500 m or less, for example, it may be 5 m, 10 m, 100 m, or the like. In consideration of productivity, a longer length of the amorphous alloy ribbon is preferable, and for example, the length is preferably 500 m to 30,000 m.

[0062] The width of the amorphous alloy ribbon is preferably 5 mm to 300 mm. When the width of the amorphous alloy ribbon is 5 mm or more, the amorphous alloy ribbon is excellent in production suitability. When the width of the amorphous alloy ribbon is 300 mm or less, the nanocrystallization uniformity is more excellent when a nanocrystalline alloy ribbon is produced by heat treatment. The width of the amorphous alloy ribbon is preferably 200 mm or less. The width of the amorphous alloy ribbon is more preferably 5 mm to 100 mm, and still more preferably 5 mm to 50 mm.

[0063] The thickness of the amorphous alloy ribbon is preferably 10 μm to 50 μm. When the thickness of the amorphous alloy ribbon is 10 μm or more, the mechanical strength of the amorphous alloy ribbon is easily ensured. When the thickness of the amorphous alloy ribbon is 50 μm or less, crystallization of a part of the structure of the amorphous alloy ribbon can be suppressed. The thickness of the amorphous alloy ribbon is more preferably 11 μm to 30 μm, and still more preferably 12 μm to 27 μm.

[0064] As the amorphous alloy ribbon, an Fe-based amorphous alloy ribbon is preferable, and an Fe-based amorphous alloy ribbon having a composition represented by the following general formula (1) is more preferable.

[0065] (Fe 1-a M a ) 100-x-y-z-α-β-γ Cu x Si y B z M' α M'' β X γ(atomic %) … General formula (1) In general formula (1), 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. a, x, y, z, α, β, and γ satisfy the following conditions, respectively: 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.

[0066] <Unwinding process> The manufacturing method of the present disclosure may include an unwinding step of unwinding an amorphous alloy strip from the coil. There are no particular limitations on the unwinding process, and it can be carried out using a known unwinding device (for example, the unwinding device 11 mentioned above).

[0067] <Amorphous alloy thin strip conveying process> The manufacturing method disclosed herein includes an amorphous alloy strip conveying step of continuously conveying an amorphous alloy strip while tension is applied to it. The operation of continuously conveying amorphous alloy strips under tension can be carried out using known conveying devices (e.g., conveying rolls). The application of tension to an amorphous alloy strip can be carried out by known methods. Tension can be applied, for example, by adjusting the unwinding speed of the amorphous alloy strip from the unwinding device and the winding speed of the winding device that winds the magnetic sheet into a coil, as described later. Alternatively, tension may be applied by providing a tension adjustment device for the amorphous alloy strip (for example, the aforementioned dancer roll 20 and bridle roll unit 21), and adjusting the unwinding speed of the amorphous alloy strip from the unwinding device and the tension adjustment device. Alternatively, tension may be applied by providing a tension adjustment device for the nanocrystalline alloy strip (for example, the bridle roll unit 40 and dancer roll 51 mentioned above) downstream of the heat treatment device, and adjusting the unwinding speed of the amorphous alloy strip from the unwinding device and the tension adjustment device.

[0068] The transport speed of the amorphous alloy strip is, for example, 1 mpm to 10 mpm, preferably 2 mpm to 8 mpm.

[0069] In this disclosure, the unit "mpm" means meters per minute ("m / min").

[0070] When tension is applied to an amorphous alloy strip, tensile stress is applied to the amorphous alloy strip. The tensile stress applied to the amorphous alloy strip is preferably 10 MPa to 60 MPa, preferably 20 MPa to 60 MPa, and preferably 30 MPa to 50 MPa.

[0071] <Heat treatment process> The manufacturing method of the present disclosure includes obtaining a nanocrystalline alloy strip by heat-treating an amorphous alloy strip by contacting it with a heated body while under tension.

[0072] The preferred transport speed of the amorphous alloy strip and the preferred range of tensile stress applied to the amorphous alloy strip in the heat treatment process are the same as the preferred range of transport speed of the amorphous alloy strip and the preferred range of tensile stress applied to the amorphous alloy strip in the amorphous alloy strip transport process.

[0073] The heat treatment in the heat treatment process is preferably carried out using a heat treatment apparatus (e.g., the heat treatment apparatus 30) that includes a heating element (e.g., the heating element 32 mentioned above) and a cooling element (e.g., the cooling element 36 mentioned above). In this case, it is preferable to bring the amorphous alloy strip, which is continuously conveyed under tension, into contact with a heating element, and then into contact with a cooling element. In this preferred embodiment, the amorphous alloy strip is heat-treated by being heated in contact with a heating element and then cooled in contact with a cooling element. As a result, nanocrystals are formed in the structure of the amorphous alloy strip during heating, or during heating and cooling, and a nanocrystalline alloy strip is obtained.

[0074] Regarding the configuration of the heat treatment apparatus, including the heating element and cooling element, for example, the configuration of the heating chamber and cooling chamber in the inline annealing apparatus described in International Publication No. 2020 / 235643 may be applied.

[0075] For example, a metal component can be used as the heating element. Examples of materials for the heating element include stainless steel, copper, copper alloys, aluminum alloys, and the like.

[0076] The temperature of the heating element should be such that heating the amorphous alloy strip yields a nanocrystalline alloy strip, and can be set appropriately considering the composition of the amorphous alloy strip, etc. The temperature of the heating element is, for example, 400°C or higher, more preferably 400°C to 800°C, and even more preferably 430°C to 700°C.

[0077] The contact time between the heated object and the amorphous alloy strip is preferably 1.0 to 10.0 seconds, more preferably 2.0 to 5.0 seconds, and even more preferably 3.0 to 4.0 seconds. The contact time between the heating element and the amorphous alloy strip is preferably set so that the temperature of the amorphous alloy strip in contact with the heating element becomes the same as the temperature of the heating element.

[0078] For example, a metal component can be used as the coolant. Examples of materials for the coolant 36 include stainless steel, Cu, Cu alloy, Al alloy, etc. The cooling body may have a cooling mechanism (e.g., a water cooling mechanism), or it may not have any special cooling mechanism (e.g., it may be a naturally occurring cooling body).

[0079] The temperature of the heating element should be such that the heated amorphous alloy strip is cooled to obtain a nanocrystalline alloy strip, and can be set appropriately considering the composition of the amorphous alloy strip, etc. The temperature of the cooling element is, for example, 350°C or less, more preferably 0°C to 300°C, and even more preferably 10°C to 250°C.

[0080] The contact time between the coolant and the amorphous alloy strip is preferably 0.3 seconds to 10.0 seconds, more preferably 0.5 seconds to 4.0 seconds, and even more preferably 1.0 seconds to 4.0 seconds.

[0081] The heating element and the cooling element may each have suction holes on the contact surface with the amorphous alloy strip. By applying reduced pressure and suction to the amorphous alloy strip through the suction holes, contact between the heating element and / or cooling element and the amorphous alloy strip can be made more stable.

[0082] The shape of the upper surfaces of the heating element 32 and the cooling element 36 is not limited to being flat. The following describes variations in the shape of the upper surfaces of the heating element and the cooling element.

[0083] Figure 12 is a conceptually enlarged partial view showing a modified example of the heat treatment apparatus. The modified heat treatment apparatus 30X shown in Figure 12 differs from the heat treatment apparatus 30 in Figure 2 in the shape of the upper surfaces of the heating element and the cooling element. Aside from this, the configuration of the heat treatment apparatus 30X is the same as that of the heat treatment apparatus 30. In detail, the shape of the upper surface of the heating element 32 in the heat treatment apparatus 30 shown in Figure 2 is flat, whereas the shape of the upper surface of the heating element 32X in the heat treatment apparatus 30X shown in Figure 12 is a curved surface that bulges upward (opposite to the direction of gravity; the same applies hereafter). More specifically, as shown in Figure 12, in a cross-section of the heating element 32X parallel to the thin strip conveying direction and parallel to the direction of gravity, the line corresponding to the upper surface of the heating element 32 is arc-shaped.

[0084] As mentioned above, tension is applied to the amorphous alloy strip 10A as it is continuously moved. Therefore, a force is easily applied to the upper surface of the curved heating element 32X, which is the case above, against the continuously transported amorphous alloy strip 10A. As a result, the contact between the amorphous alloy strip 10A and the heating element 32X is maintained more stably. This allows the amorphous alloy strip 10A to be heated more stably, and as a result, the nanocrystalline alloy strip 10B can be obtained stably.

[0085] The shape of the upper surface of the cooler 36X is the same as the shape of the upper surface of the heating element 32X described above (i.e., a curved surface that bulges upward). Furthermore, tension is applied to the amorphous alloy thin strip 10A after it has passed through the heating element 32X, so a force acts on the amorphous alloy thin strip 10A after it has passed through the heating element 32X, pressing it against the upper surface of the cooler 36X. As a result, the contact between the amorphous alloy thin strip 10A after it has passed through the heating element 32X and the cooler 36X is maintained more stably, the amorphous alloy thin strip 10A after it has passed through the heating element 32X is cooled more stably, and as a result the nanocrystalline alloy thin strip 10B is obtained stably.

[0086] As mentioned above, the cooling of the heated amorphous alloy strip can be carried out not by contact with a cooler, but for example by air cooling, so a cooler is not an essential element in this disclosure.

[0087] <Nanocrystalline alloy thin belt transport process> The manufacturing method disclosed herein includes a nanocrystalline alloy strip conveying step in which the nanocrystalline alloy strip manufactured in the heat treatment step is continuously conveyed under tension. The operation of continuously transporting nanocrystalline alloy strips under tension can be carried out using known transport devices (e.g., transport rolls). The application of tension to a nanocrystalline alloy thin strip can be carried out by known methods.

[0088] The nanocrystalline alloy thin strip conveying process preferably includes adjusting the tension of the nanocrystalline alloy thin strip using a tension adjustment device (for example, a bridle roll unit 40 and a dancer roll 51). The tension adjustment device makes it easy to adjust the tension of the nanocrystalline alloy strip coming out of the heat treatment device (i.e., the tension suitable for the heat treatment process) to the tension suitable for the subsequent bonding process. Therefore, even if the tension suitable for the heat treatment process differs from the tension suitable for the bonding process, it is easy to adjust the tension of the nanocrystalline alloy strip obtained in the heat treatment process to the tension suitable for the subsequent bonding process.

[0089] In the manufacturing method of the present disclosure, when both a tension adjustment device for nanocrystalline alloy strips (e.g., a bridle roll unit 40 and a dancer roll 51) and a tension adjustment device for amorphous alloy strips (e.g., the aforementioned dancer roll 20 and bridle roll unit 21) are used, the tension adjustment device for nanocrystalline alloy strips and the tension adjustment device for amorphous alloy strips may interact with each other to adjust the tension of the amorphous alloy strips and the tension of the nanocrystalline alloy strips. In this case, from the viewpoint of more effectively adjusting the tension, it is preferable to arrange the dancer roll 20, bridle roll unit 21, bridle roll unit 40, and dancer roll 51 in the order described above, from upstream to downstream, as in the magnetic sheet manufacturing apparatus 100.

[0090] The transport speed of the nanocrystalline alloy thin strip is, for example, 1 mpm to 10 mpm, preferably 2 mpm to 8 mpm.

[0091] When tension is applied to a nanocrystalline alloy strip, tensile stress is applied to the nanocrystalline alloy strip. The tensile stress applied to the nanocrystalline alloy strip is preferably 2 MPa to 105 MPa.

[0092] <Bonding process> The manufacturing method of the present disclosure includes a bonding step of bonding a nanocrystalline alloy strip (for example, a nanocrystalline alloy strip 10B) and an adhesive sheet (for example, the adhesive layer 60Aa in the adhesive sheet 60A with a single-sided peel-off liner shown in Figure 5) while tension is applied to obtain a laminate (for example, the laminate 70A shown in Figure 7).

[0093] The bonding of the nanocrystalline alloy strip and the adhesive sheet (for example, an adhesive sheet with a single-sided release liner; the same applies hereinafter) in the bonding process is preferably carried out using a bonding apparatus. A pair of bonding rolls (for example, bonding roll 71) is preferred as the bonding device. In this case, the nanocrystalline alloy strip and the adhesive sheet are bonded together by pressure using the pair of bonding rolls.

[0094] The preferred ranges for the transport speed of the nanocrystalline alloy strip and the tensile stress applied to the nanocrystalline alloy strip in the bonding process are the same as the preferred ranges for the transport speed of the nanocrystalline alloy strip and the tensile stress applied to the nanocrystalline alloy strip in the nanocrystalline alloy strip transport process.

[0095] In the bonding process, it is preferable to bond a nanocrystalline alloy thin strip, which is continuously transported under tension, with an adhesive sheet, which is also continuously transported under tension. This results in better bonding between the nanocrystalline alloy strip and the adhesive sheet. Furthermore, by applying tension to both the nanocrystalline alloy strip and the adhesive sheet before bonding them together, it is possible to suppress the generation of unnecessary stress in the nanocrystalline alloy strip after bonding.

[0096] The conveying speed of the adhesive sheet during the bonding process is, for example, 1 mpm to 10 mpm, preferably 2 mpm to 8 mpm.

[0097] During the bonding process, if tension is applied to the adhesive sheet, tensile stress is applied to the adhesive sheet. The tensile stress applied to the adhesive sheet is preferably 0.2 MPa to 5.0 MPa, preferably 0.5 MPa to 3.0 MPa, and preferably 1.0 MPa to 2.0 MPa.

[0098] The bonding process preferably includes adjusting the positions of both end faces in the width direction of the nanocrystalline alloy strip before bonding the nanocrystalline alloy strip to the adhesive sheet. This more effectively suppresses positional deviations in the width direction (i.e., width B mentioned above) of the continuously transported nanocrystalline alloy strip (for example, positional deviations when transported in a meandering manner). The positions of both end faces in the width direction of the nanocrystalline alloy thin strip can be adjusted using a thin strip end face position adjustment device (for example, thin strip end face position adjustment device 54; see Figures 1 and 3). Preferably, a thin strip end face detection device (for example, thin strip end face detection device 55; see Figures 1 and 3) is used to detect the positions of both end faces in the width direction of the thin strip and adjust the positions of both end faces.

[0099] The manufacturing method disclosed herein uses, as a source of adhesive sheets, An adhesive sheet with a single-sided release liner (for example, the adhesive sheet with a single-sided release liner 60A in Figure 5), which includes an adhesive sheet and a release liner (hereinafter referred to as the first release liner), In an adhesive sheet with a single-sided release liner, the release liner (hereinafter referred to as the second release liner; for example, the release liner 60B in Figure 4) is positioned on the adhesive sheet side, Preferably, the process includes a step of preparing an adhesive sheet with a double-sided release liner (for example, the adhesive sheet 60 with a double-sided release liner in Figure 4). The adhesive sheet with double-sided release liner is a laminate having a layered structure represented as "first release liner / adhesive sheet / second release liner". Regarding the structure and materials of the adhesive sheet with a double-sided release liner, known structures and materials of double-sided adhesive tapes can be appropriately applied. Preferably, the manufacturing method of the present disclosure further includes a step of peeling off a second release liner from an adhesive sheet with a double-sided release liner to obtain an adhesive sheet with a single-sided release liner. In this case, the resulting adhesive sheet with a single-sided release liner is bonded to a nanocrystalline alloy strip in the bonding process.

[0100] The adhesive sheet with a double-sided release liner is preferably a long, rectangular component. In this case, the manufacturing method of the present disclosure is The process involves setting a coil, which is made by winding a long, double-sided adhesive sheet with a release liner, into an unwinding device, The process involves unwinding an adhesive sheet with a double-sided release liner from the above coil using an unwinding machine, The process involves peeling off the second release liner from the unwound adhesive sheet with a double-sided release liner to obtain an adhesive sheet with a single-sided release liner, The process involves continuously transporting the resulting adhesive sheet with a single-sided peel-off liner while applying tension, It is preferable to include it. In this case, during the bonding process, an adhesive sheet with a single-sided peel-off liner, which is continuously transported under tension, and a thin strip of nanocrystalline alloy, which is continuously transported under tension, are bonded together.

[0101] <Crack formation process> The manufacturing method of the present disclosure includes a crack formation step of forming cracks in a nanocrystalline alloy strip (for example, a nanocrystalline alloy strip 10B in the laminate 70A shown in Figure 7) of a laminate (for example, a laminate 70A shown in Figure 7) by bringing it into contact with a crack roll (for example, a crack roll 72 shown in Figure 3), thereby obtaining a magnetic sheet (for example, a magnetic sheet 70B shown in Figure 8).

[0102] As a crack roll, a roll having multiple protrusions arranged on its circumferential surface (for example, the crack roll 72 in Figure 3) is preferred. In the crack formation process, it is preferable to perform the crack formation of the nanocrystalline alloy strip using a crack formation apparatus that includes a crack roll and a pressing roll (for example, pressing roll 73 in Figure 3) positioned opposite the crack roll.

[0103] In the manufacturing method of this disclosure, multiple crack rolls may be arranged in the transport direction of the laminate, and cracks may be formed in the nanocrystalline alloy strip of the transported laminate by the multiple crack rolls.

[0104] For crack formation in nanocrystalline alloy strips, the descriptions in paragraphs 0046 to 0065 of International Publication No. 2020 / 235643 may be applied.

[0105] <Winding process> The manufacturing method disclosed herein may include a step of winding a magnetic sheet into a coil (hereinafter also referred to as the "winding step"). This process yields a magnetic sheet wound into a coil. There are no particular limitations on the winding process, and it can be carried out using a known winding device (for example, the winding device 81 in Figures 1 and 3).

[0106] The manufacturing method disclosed herein may include steps other than those described above, as necessary.

[0107] [Magnetic sheet manufacturing equipment] The magnetic sheet manufacturing apparatus of this disclosure (for example, the magnetic sheet manufacturing apparatus 100 in Figure 1) An amorphous alloy thin strip conveying device that continuously conveys amorphous alloy thin strips while applying tension, A heat treatment apparatus comprising a heating element that comes into contact with an amorphous alloy thin strip under tension, and which heat-treats the amorphous alloy thin strip to obtain a nanocrystalline alloy thin strip, A nanocrystalline alloy thin strip transport device that continuously transports nanocrystalline alloy thin strips while tension is applied, A bonding apparatus that, under tension, bonds a nanocrystalline alloy strip and an adhesive sheet to obtain a laminate, A crack forming apparatus that includes a crack roll that contacts a nanocrystalline alloy strip of a laminate, and forms cracks in the nanocrystalline alloy strip of the laminate to obtain a magnetic sheet, including, This is a magnetic sheet manufacturing device. The magnetic sheet manufacturing apparatus of this disclosure may include elements (devices or components) other than those described above, as necessary.

[0108] The magnetic sheet manufacturing apparatus of this disclosure is suitable as the apparatus in the manufacturing method of this disclosure described above. Therefore, the magnetic sheet manufacturing apparatus of this disclosure can efficiently manufacture the magnetic sheet described above.

[0109] The magnetic sheet manufacturing apparatus of this disclosure preferably includes a thin sheet end face position adjustment device (for example, the thin sheet end face position adjustment device 54 in Figures 1 and 3) between the heat treatment apparatus and the bonding apparatus for adjusting the positions of both end faces in the width direction of the nanocrystalline alloy thin sheet. This makes it possible to more effectively suppress misalignment during bonding between the nanocrystalline alloy strip and the adhesive sheet (specifically, misalignment in the width direction of the nanocrystalline alloy strip).

[0110] The magnetic sheet manufacturing apparatus of this disclosure preferably includes a tension adjustment device (for example, the dancer roll 20 and bridle roll unit 21 in Figure 1) between the heat treatment apparatus and the bonding apparatus for adjusting the tension of the nanocrystalline alloy strip. This makes it easier to adjust the tension of the nanocrystalline alloy strip coming out of the heat treatment device (i.e., the tension suitable for the heat treatment process) to the tension suitable for the subsequent bonding process. Therefore, even if the tension suitable for the heat treatment process and the tension suitable for the bonding process are different, it is easy to adjust the tension of the nanocrystalline alloy strip obtained in the heat treatment process to the tension suitable for the subsequent bonding process.

[0111] A preferred embodiment of the magnetic sheet manufacturing apparatus of this disclosure can be applied to the preferred embodiment of the manufacturing method of this disclosure described above. [Examples]

[0112] Hereinafter, examples of the present invention will be shown, but the present invention is not limited to the following examples.

[0113] [Examples 1 and 2] As Examples 1 and 2, specific examples of manufacturing conditions are shown assuming a case where a magnetic sheet manufacturing apparatus having the same configuration as the magnetic sheet manufacturing apparatus 100 shown in Fig. 1 is used to manufacture a magnetic sheet having the same configuration as the magnetic sheet 170B shown in Fig. 11. As the amorphous alloy ribbon, for example, in the above-described general formula (1) (that is, "(Fe 1-a M a ) 100-x-y-z-α-β-γ Cu x Si y B z M’ α M” β X γ (atomic %) ... general formula (1)"), an FeCuNbSiB amorphous alloy ribbon in which a, x, y, z, α, β, and γ satisfy a=0, 0.1≦x≦3, 0<y≦30, 0<z≦25, 5≦y+z≦30, 0<α≦20, β=0, and γ=0, respectively, is used. As the pressure-sensitive adhesive sheet, for example, a double-sided pressure-sensitive adhesive tape including a support and pressure-sensitive adhesive layers provided on both sides of the support (that is, the pressure-sensitive adhesive sheet 160Aa in the pressure-sensitive adhesive sheet 160 with a double-sided release liner shown in Fig. 10) is used. The width of the pressure-sensitive adhesive sheet in Table 1 means the width of the double-sided pressure-sensitive adhesive tape, and this width is assumed to be equal to the width of the support in the double-sided pressure-sensitive adhesive tape.

[0114]

Table 1

Explanation of Symbols

[0115] 10 A coil formed by winding an amorphous alloy ribbon 10A Amorphous alloy ribbon 10B Nanocrystalline alloy ribbon 10BA Nanocrystalline alloy ribbon having cracks 10BB Crack 11. Unwinding device 12-15 Conveyor Rolls 20 Dancer Roll 21 Bridle Roll Unit 21A~21C Bridle Roll 22 Thin strip end face detection device 23 Thin strip end face detection device 24. Tension detection device 25 Ribbon end face position adjustment device 30, 30X heat treatment equipment 31, 34, 35, 38 Pair of guide rolls 32, 32X heating element 33 Heating device 36, 36X cooling body 37 Cooling device 40 Bridle Roll Unit 40A~40C Bridle Roll 41-46 Conveyor Rolls 50 Ribbon edge position adjustment device 51 Dancer Roll 52 Thin strip end face detection device 54 Ribbon end face position adjustment device 55 Thin strip end face detection device 60 double-sided adhesive sheets with release liner 60A Adhesive sheet with single-sided release liner 60Aa Adhesive layer (adhesive sheet) 60Ab release liner 60B Release Liner 61 Unwinding device 62 Winding device 63-65 Conveyor Rolls 70A laminate 70B, 170B Magnetic Sheets 71. Laminating Roll (Laminating Device) 72 Crack Roll 73 Pressing Roll 74 Nip Roll 75 Flattening Roll 76-78 Conveyor Rolls 81 Winding device 100 Magnetic Sheet Manufacturing Equipment 160 Double-sided adhesive sheets with release liner 160A Adhesive sheet with single-sided release liner 160Aa1 Support 160Aa2 adhesive layer 160Aa Double-sided adhesive tape (adhesive sheet) 160Ab release liner 170B Magnetic Sheet

Claims

1. An amorphous alloy thin strip conveying process in which an amorphous alloy thin strip is continuously conveyed under tension, A heat treatment step to obtain a nanocrystalline alloy strip by heat-treating the amorphous alloy strip by bringing it into contact with a heated body while tension is applied, A nanocrystalline alloy thin strip transport process in which the nanocrystalline alloy thin strip is continuously transported while tension is applied, A bonding step to obtain a laminate by bonding the nanocrystalline alloy thin strip and the adhesive sheet while tension is applied, A crack formation step is performed to form cracks in the nanocrystalline alloy strip of the laminate by bringing it into contact with a crack roll in order to obtain a magnetic sheet, Includes, The nanocrystalline alloy thin strip transport process includes a tension adjustment process in which the tension of the nanocrystalline alloy thin strip is adjusted by a tension adjustment device. The bonding step, after the tension adjustment step and before bonding the nanocrystalline alloy strip and the adhesive sheet, includes a strip end face position adjustment step in which the positions of both end faces in the width direction of the nanocrystalline alloy strip are detected and the positions of both end faces in the width direction of the nanocrystalline alloy strip are adjusted. The amorphous alloy thin strip transport step, the heat treatment step, the nanocrystalline alloy thin strip transport step, the bonding step, and the crack formation step are carried out in succession in that order. A method for manufacturing magnetic sheets.

2. When the width of the adhesive sheet is denoted as width A and the width of the nanocrystalline alloy thin strip as width B, the value obtained by subtracting width B from width A is between 0.2 mm and 3.0 mm. A method for manufacturing a magnetic sheet according to claim 1.

3. The method for manufacturing a magnetic sheet according to claim 1 or 2, wherein the adhesive sheet is made up of an adhesive layer or is a double-sided adhesive tape including a support and adhesive layers provided on both sides of the support.

4. An amorphous alloy thin strip conveying device that continuously conveys amorphous alloy thin strips while applying tension, A heat treatment apparatus comprising a heating element that comes into contact with the amorphous alloy thin strip under tension, the amorphous alloy thin strip being heat-treated to obtain a nanocrystalline alloy thin strip, A nanocrystalline alloy thin strip transport device that continuously transports the nanocrystalline alloy thin strip while tension is applied, A bonding device that, without winding up the nanocrystalline alloy thin strip that has been continuously conveyed by the nanocrystalline alloy thin strip conveying device, applies tension to the nanocrystalline alloy thin strip and an adhesive sheet to obtain a laminate, A crack forming apparatus comprising a crack roll that contacts the nanocrystalline alloy strip of the laminate, wherein cracks are formed in the nanocrystalline alloy strip of the laminate to obtain a magnetic sheet, Includes, A tension adjustment device for adjusting the tension of the nanocrystalline alloy strip is included between the heat treatment apparatus and the bonding apparatus. Between the tension adjustment device and the bonding device, there is a thin strip end face detection device for detecting the positions of both end faces in the width direction of the nanocrystalline alloy thin strip, and a thin strip end face position adjustment device for adjusting the positions of both end faces in the width direction of the nanocrystalline alloy thin strip. Magnetic sheet manufacturing equipment.

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