JP4807523B2 - Sheet-like soft magnetic material and method for producing the same - Google Patents

Description

  The present invention relates to a sheet-like soft magnetic material having excellent magnetic properties and small thickness change and a method for producing the same.

  The manufacture of soft magnetic sheets used in various electronic devices is generally performed by a kneading and rolling method. In this method, flat soft magnetic powder, rubber, and a binder such as chlorinated polyethylene are kneaded at a predetermined ratio with a kneader, and the obtained kneaded product is rolled to a predetermined thickness with an apparatus such as a calender roll, and further required. Accordingly, the binder is heated and crosslinked to obtain a single-layer soft magnetic sheet. This method has the advantage that the soft magnetic powder can be filled at a high density, the soft magnetic powder can be oriented in the in-plane direction by rolling, and the sheet thickness can be easily adjusted.

  However, in the case of the kneading and rolling method, since the soft magnetic powder is distorted during kneading, there is a problem that the magnetic properties of the soft magnetic powder itself are lowered and the magnetic permeability of the soft magnetic sheet cannot be increased. Further, there has been a problem that the magnetic permeability is lowered by changing the sheet thickness in a high temperature or high temperature and high humidity environment.

  Therefore, instead of the kneading and rolling method, a soft magnetic sheet is manufactured by a coating method in which the soft magnetic powder is less likely to be distorted (Patent Document 1). In this method, a liquid composition for forming a soft magnetic sheet consisting of flat soft magnetic powder, rubber, resin and solvent is applied onto a release substrate and dried, so that the sheet thickness can be increased even in a high temperature or high temperature and high humidity environment. A soft magnetic sheet with little change is obtained.

JP 2000-243615 A

  However, the coating method is suitable for producing a soft magnetic sheet having a relatively thin sheet thickness, but is not suitable for producing a relatively thick soft magnetic sheet. This is because when the coating is thick, uneven coating thickness tends to occur and drying becomes difficult. For this reason, the present inventors blended a curable resin and its curing agent with a liquid composition for soft magnetic sheet formation, created a thin curable soft magnetic sheet by a coating method, and cured a plurality of the sheets. An attempt was made to produce a laminated sheet-like soft magnetic material by compressing while compressing. However, the laminated soft magnetic sheet produced by laminating thin soft magnetic sheets produced by the coating method is relatively thick manufactured by the kneading rolling method, although the change in the thickness of each thin soft magnetic sheet is small. Similar to the single-layer soft magnetic sheet, there is a problem in that the sheet thickness increases in a high temperature or high temperature and high humidity environment, and the magnetic permeability decreases.

  The present invention is intended to solve the above-described problems of the prior art, and is formed by laminating a plurality of thin curable soft magnetic sheets prepared by a coating method on a sheet-like soft magnetic material. However, it is an object to provide a configuration in which a change in sheet thickness is suppressed even in a high-temperature or high-temperature and high-humidity environment, and variation in magnetic permeability is reduced.

The present invention which has achieved this object is a sheet-like soft magnetic material formed from a soft magnetic composition comprising at least a flat soft magnetic powder, an acrylic rubber, an epoxy resin, a curing agent for epoxy resin, and a solvent. Material,
The flat soft magnetic powder is arranged in an in-plane direction of the sheet-like soft magnetic material;
Acrylic rubber has glycidyl groups,
The sheet-like soft magnetic material is characterized in that the weight ratio of the flat soft magnetic powder to the total amount of the acrylic rubber, the epoxy resin, and the epoxy resin curing agent is 3.7 to 5.8.

  Here, the preferable aspect of the sheet-like soft magnetic material of this invention is an aspect which uses Fe-Si-Cr-Ni alloy powder and / or Fe-Si-Al alloy powder as flat soft magnetic powder. Moreover, another preferable aspect is an aspect which uses the hardening | curing agent which shows latency as a hardening | curing agent for epoxy resins. Still another preferred embodiment is an embodiment in which the sheet-like soft magnetic material has no rolling history, an embodiment in which the tensile strength is 20 Mpa or more and 50 MPa or less, or an embodiment in which the glossiness at an incident angle of 60 degrees is 20% or more and 50% or less. .

  Further, the present invention provides a soft magnetic composition obtained by mixing at least a flat soft magnetic powder, an acrylic rubber having a glycidyl group, an epoxy resin, a curing agent for an epoxy resin, and a solvent. Is applied onto a release substrate at a temperature that does not proceed to, and then dried to create a curable soft magnetic sheet. Two or more curable soft magnetic sheets are laminated to obtain a laminate, and laminated at a temperature at which a curing reaction occurs. Provided is a method for producing a sheet-like soft magnetic material, wherein the product is compressed so as not to be rolled.

  The sheet-like soft magnetic material of the present invention is formed from a soft magnetic composition comprising flat soft magnetic powder, acrylic rubber having a glycidyl group, an epoxy resin, a curing agent for epoxy resin, and a solvent. Here, since the acrylic rubber having a glycidyl group reacts with the epoxy resin, the cohesive force of molecules constituting the sheet-like soft magnetic material can be further increased. Moreover, the acrylic rubber and epoxy resin used as a binder are excellent also in heat resistance and moisture resistance. Therefore, the sheet-like soft magnetic material of the present invention can realize good dimensional stability over a long period of time in a high temperature and high humidity environment. Moreover, since the flat soft magnetic powder is arranged in the in-plane direction of the sheet-like soft magnetic material, the magnetic characteristics are improved.

  The sheet-like soft magnetic material of the present invention is formed from a soft magnetic composition formed by mixing at least flat soft magnetic powder, acrylic rubber, an epoxy resin, an epoxy resin curing agent, and a solvent. .

  In the present invention, a flat soft magnetic powder (flat soft magnetic powder) is used. By arranging the flat soft magnetic powder in a two-dimensional in-plane direction, a high magnetic permeability and a large specific gravity can be realized.

  As a raw material of the flat soft magnetic powder, any soft magnetic alloy can be used, for example, magnetic stainless steel (Fe—Cr—Al—Si alloy), sendust (Fe—Si—A1 alloy), permalloy (Fe—Ni). Alloy), silicon copper (Fe—Cu—Si alloy), Fe—Si alloy, Fe—Si—B (—Cu—Nb) alloy, Fe—Si—Cr—Ni alloy, Fe—Si—Cr alloy, Fe— Si-Al-Ni-Cr alloy, ferrite, etc. are mentioned. Among these, Fe-Si-Al alloys or Fe-Si-Cr-Ni alloys can be preferably used from the viewpoint of magnetic properties.

  When these soft magnetic alloys are used for RFID communication, the real part (permeability) μ ′ of the complex relative permeability is relatively large, and the imaginary part (magnetic loss) μ ″ of the complex relative permeability is It is preferable to use one having a relatively small numerical value, whereby the magnetic field emitted from the antenna coil for RFID communication is prevented from being converted into eddy current loss by the metal body, and communication performance is improved.

  In addition, it is preferable to use a flat soft magnetic alloy having a relatively large resistance in order to reduce the value of μ ″ for the purpose of reducing eddy current loss. In this case, the composition of the soft magnetic alloy is changed. For example, in the case of an Fe—Si—Cr alloy or Fe—Si—Al alloy, the Si content is preferably 9 to 15% by weight.

As the flat soft magnetic powder, a soft magnetic powder having a flat shape is used. Preferably, the average particle diameter is 3.5 to 100 μm, the average thickness is 0.3 to 3.0 μm, and more preferably the average particle diameter is 10. ˜100 μm, average thickness is 0.5˜2.5 μm. Therefore, the flatness (flatness) is preferably set to 8 to 80, more preferably 15 to 65. Here, the flatness ratio is a numerical value calculated by multiplying a numerical value (μm) of 50% particle size (D50) by a numerical value (cm ² / g) of a specific surface area described later. In addition, what is necessary is just to classify | classify using a sieve etc. as needed in order to arrange the magnitude | size of a flat soft magnetic powder. Further, in order to increase the magnetic permeability of the soft magnetic material, to increase the particle size of the flat soft magnetic powder, and reduce the distance between the particles, the soft magnetic powder to enhance and flat aspect ratio of the soft magnetic powder it is effective to reduce the influence of the anti-magnetic field.

The tap density (JIS K-5101) and the specific surface area (BET method) of the flat soft magnetic powder are in inverse proportion to each other. However, if the specific surface area becomes too large, not only the value of μ ′ but also the μ The value of ″ also tends to be too large. Conversely, if it is too small, the value of μ ′ tends to be too small. If the tap density is too small, the coating of soft magnetic powder is possible even if a large amount of solvent is used. The composition is difficult to apply, and if it is too large, μ ′ tends to decrease.Therefore, the numerical range thereof is set to a preferable range, specifically, the tap density is preferably 0.55 to 1.45 g /. ml, more preferably 0.65 to 1.40 g / ml, while the specific surface area is preferably 0.40 to 1.20 m ² / g, more preferably 0.65 to 1.00 m ² / g. Set.

  Further, as the flat soft magnetic powder, for example, a soft magnetic powder that has been coupled with a coupling agent such as a silane coupling agent may be used. By using the soft magnetic powder subjected to the coupling treatment, the reinforcing effect of the interface between the flat soft magnetic powder and the binder can be enhanced, and the specific gravity and corrosion resistance can be improved. As the coupling agent, for example, γ-methacryloxypropyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropylmethyldiethoxysilane and the like can be used. This coupling process may be performed on the soft magnetic powder in advance, or when the flat soft magnetic powder and the binder resin are mixed, the coupling process is performed as a result. May be.

  If the amount of the flat soft magnetic powder used in the soft magnetic composition is too small, the intended magnetic properties cannot be obtained. If the amount is too large, the amount of the binder resin is relatively small and the moldability is decreased. Is 70 to 90% by weight, more preferably 80 to 85% by weight in the soft magnetic composition excluding.

The soft magnetic composition uses acrylic rubber as a rubber component in order to impart good flexibility and heat resistance to the sheet-like magnetic material. The acrylic rubber always has one or more glycidyl groups in order to improve the reactivity with the epoxy resin. The acrylic rubber preferably further has a hydroxy group. Adhesion at the time of laminating a plurality of thin soft magnetic sheets can be improved. The number average molecular weight of such an acrylic rubber is preferably 50,000 to 300,000, and the weight average molecular weight is preferably 100,000 to 450,000. The glass transition temperature is preferably −10 to 15 ° C. The melt viscosity is preferably 1500 to 15000 mPa · s (25 ° C.). The hydroxyl value is preferably 6 to 10 mgKOH / g. Specific examples of such acrylic rubber include EA-AN, BA-EA-AN, BA-MMA, BA-AN and the like.

  If the amount of acrylic rubber used in the soft magnetic composition is too small, the flexibility becomes poor, and if it is too large, the elasticity of the rubber increases and the compressibility deteriorates (decrease in heat processability). It is 9 to 16% by weight in the soft magnetic composition, more preferably 12 to 14% by weight.

  The soft magnetic composition uses an epoxy resin in order to impart good heat processability and dimensional stability to the sheet-like soft magnetic material. As an epoxy resin, the epoxy resin conventionally used in the soft magnetic sheet can be used. Specific examples include phenol novolak, tetraglycidyl phenol, O-cresol novolak, tetraglycidyl amine, bisphenol A, bis A glycidyl ether, bisphenol F, and the like. The epoxy equivalent of these epoxy resins is preferably 180 to 220 g / eq.

  If the amount of the epoxy resin used in the soft magnetic composition is too small, sufficient heat processability cannot be obtained, and if it is too large, flexibility is impaired. It is 0 to 6.0% by weight, more preferably 1.5 to 4.0% by weight.

  The soft magnetic composition uses an epoxy resin curing agent to cure the epoxy resin. As the curing agent for epoxy resin, a curing agent for epoxy resin that has been conventionally used in soft magnetic sheets can be used. Specific examples include amines, imidazole, polyamide, phenolic acid anhydride and the like. These are preferably latent.

  If the amount of the curing agent for the epoxy resin in the soft magnetic composition is too small, the reliability of the product is lowered (decrease in storage characteristics). The amount is preferably 3 to 100 parts by weight, more preferably 10 to 40 parts by weight, based on 100 parts by weight of the epoxy resin.

  As the solvent, a general general-purpose solvent can be used. For example, alcohols such as ethanol, n-propanol, isopropyl alcohol (IPA) and n-butyl alcohol, esters such as ethyl acetate and n-butyl acetate, Acetone, methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), ketones such as cyclohexanone, ethers such as tetrahydrofuran (THF), ethyl cellosolve, n-butyl cellosolve, cellosolves such as cellosolve acetate, toluene, xylene, benzene, etc. General-purpose solvents such as aromatic hydrocarbons can be used. The amount used can be appropriately selected according to the type of composition of the soft magnetic composition, the coating method, and the like.

  The weight ratio of the flat soft magnetic powder to the total amount of the acrylic rubber, the epoxy resin, and the epoxy resin curing agent is 3.7 to 5.8, preferably 4.0 to 5.3. If it is less than 3.7, μ ′ will not be sufficiently large, and if it exceeds 5.8, thickness variation will occur on the coated surface due to insufficient binder components, thermal workability will deteriorate, and streaks will occur during coating. Because it enters. Further, when the amount of acrylic rubber is relatively increased with respect to the amount of epoxy resin, the sheet-like soft magnetic material becomes soft, and when the amount of epoxy resin is relatively increased, it becomes hard. Accordingly, when a relatively large amount of epoxy resin is used relative to acrylic rubber, a highly reliable sheet-like soft magnetic material can be obtained.

  The soft magnetic composition can be prepared by uniformly mixing the above-described components by a conventional method.

  Further, in the sheet-like soft magnetic material of the present invention, the flat soft magnetic powder is arranged in the in-plane direction of the sheet-like soft magnetic material. Thereby, magnetic characteristics can be improved and specific gravity can be increased. Arranging in the in-plane direction means that a curable soft magnetic sheet (2) obtained by applying the soft magnetic composition onto the release substrate when the sheet-like soft magnetic material is prepared from the soft magnetic composition described above. This can be achieved by compressing the layer (including the case of laminating more than one layer). In this case, although it compresses, it does not extend in a two-dimensional direction, that is, does not roll. Specifically, the linear elongation rate in the planar direction should not exceed 1%. If the rolling exceeds 1%, the thickness will vary, the μ 'and specific gravity will also vary, and shape defects such as wrinkles and cracks, insufficient filling of soft magnetic powder, and orientation failure will occur. This is because μ ′ does not increase.

If the tensile strength of the sheet-like soft magnetic material of the present invention is too small, the compression is insufficient and the soft magnetic powder is not tightly packed, so air is mixed inside the sheet, and the thickness change may increase. is concerned, and an excessively large and the sheet is too compressed, the sheet becomes hard, since there is a possibility that flexibility is impaired, preferably 20M P a higher 50MPa or less, more preferably below 25M P a higher 45MPa is there. As a result, when the tensile strength is within this range, the sheet itself has a strain while having appropriate flexibility, excellent workability and handleability, and when incorporating a sheet-like soft magnetic material into an electronic device or the like. There is an advantage that the yield is not lowered. As a method of setting the tensile strength within this range, it can be performed by adjusting the pressing pressure and the blending amount of the soft magnetic powder. The tensile strength can be measured by a known method.

  In addition, if the glossiness of the sheet-like soft magnetic material of the present invention is too small, the soft magnetic powder may fall off not only from the sheet cross section but also from the sheet surface, and since it is not sufficiently compressed, Since air is mixed into the sheet and moisture easily penetrates into the sheet, and the sheet thickness increases in a high temperature or high temperature and high humidity environment, the magnetic characteristics may be deteriorated. Conversely, if it is too large, the sheet is sufficiently compressed and the surface becomes smooth, but the sheet becomes hard. Therefore, the glossiness is preferably 20% to 50%, more preferably 23% to 48% at an incident angle of 60 degrees. As a result, when the glossiness is within this range, there is an advantage that the thickness change and the magnetic property change can be reduced even in a high-temperature and high-humidity environment with the sheet having flexibility. As a method for setting the gloss level within this range, it is possible to perform the selection by selecting the type of the cushioning material used at the time of pressing, the size of the unevenness, the size of the pressure, and the like. The glossiness can be measured according to JIS Z8741 or JIS P8142.

Further, the linear expansion coefficient of the sheet-like soft magnetic material of the present invention tends to be too soft if the sheet is too large , and tends to be too hard if it is too small , preferably 15 to 22 ppm / ° C. Preferably it is 16-21 ppm / degrees C. Further, the difference in coefficient of linear expansion between the adherend and the sheet-like soft magnetic material is set to 10 ppm / ° C. or less. Thereby, both linear expansion coefficients can be made substantially equal, and even if heating and cooling are repeated, peeling can be made difficult. For example, when an antenna and a sheet-like magnetic material are laminated using an adhesive, the occurrence of a peeling problem can be greatly suppressed, and good flatness can be realized. In addition, the sheet-like soft magnetic material composed of acrylic rubber, epoxy resin, and latent curing agent has low hygroscopicity, so even if the sheet-like soft magnetic material of the present invention is affixed to a conductor, which is an adherend, it will rust. Can be suppressed.

  Next, the preferable example of the manufacturing method of the sheet-like soft magnetic material of this invention is demonstrated. In this production method, a soft magnetic composition obtained by mixing at least a flat soft magnetic powder, an acrylic rubber having a glycidyl group, an epoxy resin, a curing agent for epoxy resin, and a solvent is substantially cured. A curable soft magnetic sheet is prepared by applying onto a release substrate at a temperature that does not proceed and drying, and a laminate is obtained by laminating two or more curable soft magnetic sheets, and the laminate is obtained at a temperature at which a curing reaction occurs. The sheet-like soft magnetic material is manufactured by compressing so as not to be rolled.

  In this production method, first, a soft magnetic composition is applied onto a release substrate at a temperature at which the curing reaction does not substantially proceed and dried to obtain a curable soft magnetic sheet. As a method for applying the soft magnetic composition onto the release substrate, a known method such as a doctor blade coating method or a comma coater coating method can be used. The coating thickness can be appropriately determined according to the use of the sheet-like soft magnetic material and the number of laminated layers, but it is usually applied at a thickness that results in a dry thickness of 50 to 200 μm. It should be noted that it is difficult to dry when applied in a thickness exceeding 200 μm, and the sheet may swell during drying.

  The reason for applying and drying at a temperature at which the curing reaction of the soft magnetic composition does not substantially proceed is that when the curing reaction proceeds, the compressibility deteriorates, μ ′ does not increase, and when the curing reaction has progressed, This is because the thickness change in a high temperature and high humidity environment becomes large. Here, “the curing reaction does not substantially proceed” means that the crosslinking reaction can be uniformly formed in the final step. The specific temperature varies depending on the composition of the soft magnetic composition, but is usually 130 ° C. or lower. As a specific method of drying, a known method using a hot air drying furnace, an electric heating furnace, infrared heating or the like can be employed.

  As the release substrate, a normal release substrate can be used. For example, a polyester sheet whose surface has been subjected to a silicone release treatment can be used.

  Next, two or more curable soft magnetic sheets are prepared and laminated to obtain a laminate. The number of layers is determined by the use of the sheet-like soft magnetic material. Moreover, when laminating, it is preferable to arrange release sheets on both sides of the laminate of soft magnetic sheets. As the release sheet in this case, a polyester sheet or the like whose surface is subjected to silicone release treatment can be used. In addition, when laminating | stacking two or more layers, the press which pressurizes the whole sheet | seat integrally can be used. In this case, if the press pressure is too high, the glossiness and the tensile strength increase, but the flexibility tends to decrease. In addition, when a laminator that applies linear pressure is used instead of a press, the glossiness and tensile strength tend to be low.

  Next, the laminate obtained as described above is compressed so as not to be rolled at a temperature at which a curing reaction occurs. As a result, a sheet-like soft magnetic material is obtained in which the change in sheet thickness is suppressed and the variation in magnetic permeability is small.

  The reason for compressing so as not to roll is that, as described above, the thickness varies when rolled, the μ 'and specific gravity also vary, the shape is poor such as wrinkles and cracks, the soft magnetic powder is insufficiently filled, This is because μ ′ does not increase due to poor alignment. The reason for heating to “the temperature at which the curing reaction of the laminate occurs” is to crosslink in a highly filled and highly oriented state. Although specific temperature changes with compositions of a soft-magnetic composition, it is 100-200 degreeC normally, Preferably it is 140-180 degreeC.

As a method of compressing, a laminator that applies linear pressure with two rolls may be used. However, it is preferable to use a press machine that has a flat surface and can be heated in order to suppress stretching. In this case, the value of the compression pressure varies depending on the material of the curable soft magnetic sheet, the number of laminated layers, and the like, but is preferably 10 to 50 kgf / cm ² , more preferably 20 to 40 kgf / cm ² . Also, lamination and compression can be performed simultaneously.

  Hereinafter, the present invention will be specifically described by way of examples.

Example 1
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 500 parts by weight, acrylic rubber having glycidyl group (SG80H-3, manufactured by Nagase ChemteX Corporation; weight average molecular weight 350,000, Tg 7.5 ° C.) 75.5 parts by weight, epoxy resin (Epicoat 1031S, Japan Epoxy Resin) Co., Ltd.) 21 parts by weight, epoxy resin latent curing agent (HX3748, Asahi Kasei Chemicals Co., Ltd.) 6.3 parts by weight, toluene 270 parts by weight and ethyl acetate 120 parts by weight. The coated soft magnetic composition was applied on a polyester film (peeled PET) having a surface treated with a coater, and dried at a temperature of less than 80 ° C. There was dried at 100 ° C., the thickness of the sheet after drying to obtain a curable soft magnetic sheet before and after the 100 [mu] m.

Prepare four sheets of peeled PET removed from the obtained curable soft magnetic sheet, laminate them, sandwich both sides of the laminate with peeled PET, and buffer 100 μm thick fine paper on both sides The sheet-like soft magnetic material was placed on both sides with two stainless steel (SUS) plates and compressed with a vacuum press (made by Kitagawa Seiki) at 24.9 kgf / cm ² at 165 ° C. for 10 minutes. Obtained.

(Evaluation)
When the obtained sheet-shaped soft magnetic material was subjected to a heat resistance test (stands in an oven at a temperature of 85 ° C. and a humidity of 60 Rh% for 96 hours), the thickness of the sheet-shaped soft magnetic material after the heat resistance test changed to become thinner. However, the rate of change was less than 2% based on the sheet-like soft magnetic material before the heat resistance test. The effective magnetic permeability μ ′ was 34 or more and less than 38 and the magnetic loss μ ″ was less than 1.5. The obtained results are shown in Table 1. Table 1 also shows acrylic rubber and epoxy resin. The weight ratio of the flat soft magnetic powder to the total amount of the epoxy resin curing agent and the epoxy resin curing agent (magnetic powder / resin weight ratio) is also shown.

  In addition, a ring-shaped sample punched into an outer diameter of 7.05 mm and an inner diameter of 2.945 mm was produced, and a conductive wire coil was wound around this for 5 turns and soldered to a terminal. The length from the base of the terminal to the bottom of the ring-shaped sample was 20 mm. Regarding the effective magnetic permeability μ ′, the inductance and resistance values at the carrier frequency (13.56 MHz) were measured using an impedance analyzer (4294A, Agilent Technologies), and the magnetic permeability was calculated. The obtained results are shown in Table 1.

  Furthermore, the glossiness at an incident angle of 60 degrees (−60 degrees) of the obtained sheet-like soft magnetic material was measured using a gloss meter (VG2000, Nippon Denshoku Industries Co., Ltd.) based on JIS Z8741 or JIS P8142. The glossiness is desirably 20 to 50%. The obtained results are shown in Table 1.

  About the tensile strength of the obtained sheet-like soft magnetic material, using a tensile tester (Tensilon, Orientec Co., Ltd.), a sample having a thickness of 250 μm, a width of 25 mm, and a length of 100 mm was applied at a load of 50 kgf and a tensile speed of 10 mm / min. Measured under conditions. The tensile strength is desirably 20 to 50 MPa. The obtained results are shown in Table 1.

The electrical resistance of the obtained sheet-like soft magnetic material was measured using an electrical resistance measuring device (Hiresta P MCP HP260, Dia Instruments Co., Ltd.). The electrical resistance is desirably 1 × 10 ⁴ Ω or more. The obtained results are shown in Table 1.

  In addition, the presence or absence of powder falling of the obtained sheet-like soft magnetic material (a phenomenon in which soft magnetic powder falls off and adheres when the magnetic sheet is touched) was visually observed, and the observation results are shown in Table 1. It is desirable that no powder fall is observed.

  Further, regarding the softness of the obtained sheet-like soft magnetic material, a test was performed by bending a 250 mm square sheet in half, and the case where it was folded was evaluated as “bad”, and the case where it was not folded was evaluated as “good”. The evaluation results are shown in Table 1. It is hoped that it will not break.

  About the linear expansion coefficient of the obtained sheet-like soft magnetic material, it measured using the thermal / stress / strain measuring apparatus (EXSTA6000TMA / SS, SSI nanotechnology company). The linear expansion coefficient is desirably 15 to 22 ppm / ° C. The obtained results are shown in Table 1.

  About the obtained sheet-like soft magnetic material, glossiness, tensile strength, electrical resistance, powder fall, flexibility, and coefficient of linear expansion all showed good results.

Example 2
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 425 parts by weight, glycidyl group-containing acrylic rubber (SG80H-3, manufactured by Nagase ChemteX Corporation) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, A soft magnetic composition composed of 6.7 parts by weight of a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate is applied onto the peeled PET with a coater. And dried at a temperature of less than 80 ° C., followed by drying at 100 ° C. to obtain a curable soft magnetic sheet having a thickness of about 100 μm after drying.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness after the heat test was changed to be thinner, but the rate of change was less than 2%. The value of the magnetic permeability μ ′ was 34 or more and less than 38 and the magnetic loss μ ″ was less than 1.5. Also, the glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient were all good. Results are shown.

Example 3
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 450 parts by weight, acrylic rubber having glycidyl group (SG80H-3, manufactured by Nagase ChemteX Corporation) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, A soft magnetic composition composed of 6.7 parts by weight of a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate is applied onto the peeled PET with a coater. And dried at a temperature of less than 80 ° C., followed by drying at 100 ° C., to obtain a curable soft magnetic sheet having a dried sheet thickness of about 100 μm.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness after the heat test changed to be thicker, but the rate of change was less than 1%. The value of magnetic permeability μ ′ was 38 or more and less than 40 and the magnetic loss μ ″ was less than 1.5. Good results were obtained for glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient. Indicated.

Example 4
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 475 parts by weight, glycidyl group-containing acrylic rubber (SG80H-3, manufactured by Nagase ChemteX Corporation) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, A soft magnetic composition composed of 6.7 parts by weight of a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate is applied onto the peeled PET with a coater. And dried at a temperature of less than 80 ° C., followed by drying at 100 ° C., to obtain a curable soft magnetic sheet having a dried sheet thickness of about 100 μm.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness after the heat test changed to be thinner, but the rate of change was less than 1%. The value of the magnetic permeability μ ′ was 38 or more and less than 40 and the magnetic loss μ ″ was less than 1.5. Also, the glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient were all good. Results are shown.

Example 5
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 510 parts by weight, glycidyl group-containing acrylic rubber (SG80H-3, manufactured by Nagase ChemteX Corporation) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, A soft magnetic composition composed of 67 parts by weight of a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Co., Ltd.), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate was applied onto release PET with a coater. Drying was performed at a temperature of less than 80 ° C., followed by drying at 100 ° C. to obtain a curable soft magnetic sheet having a sheet thickness of about 100 μm after drying.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness did not change even after the heat resistance test. The value of the magnetic permeability μ ′ was 40 or more and the magnetic loss μ ″ was less than 1.5. The results obtained are shown in Table 1. Also, the glossiness, tensile strength, electrical resistance, powder fall, flexibility, The linear expansion coefficient showed good results.

Example 6
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 530 parts by weight, glycidyl group-containing acrylic rubber (SG80H-3, manufactured by Nagase ChemteX Corporation) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, A soft magnetic composition composed of 6.7 parts by weight of a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate is applied onto the peeled PET with a coater. And dried at a temperature of less than 80 ° C., followed by drying at 100 ° C., to obtain a curable soft magnetic sheet having a dried sheet thickness of about 100 μm.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness changed to be thicker after the heat test, but the rate of change was less than 1%. The value of the magnetic permeability μ ′ was 40 or more and the magnetic loss μ ″ was less than 1.5. Also, the glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient were all good. Indicated.

Example 7
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 550 parts by weight, glycidyl group-containing acrylic rubber (SG80H-3, manufactured by Nagase ChemteX Corp.) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, A soft magnetic composition composed of 6.7 parts by weight of a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate is applied onto the peeled PET with a coater. And dried at a temperature of less than 80 ° C., followed by drying at 100 ° C., to obtain a curable soft magnetic sheet having a dried sheet thickness of about 100 μm.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness changed to be thicker after the heat test, but the rate of change was less than 1%. The value of the magnetic permeability μ ′ was 40 or more and the magnetic loss μ ″ was less than 1.5. Also, the glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient were all good. Indicated.

Example 8
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 575 parts by weight, acrylic rubber having a glycidyl group (SG80H-3, manufactured by Nagase ChemteX Corporation) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, A soft magnetic composition composed of 6.7 parts by weight of a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate is applied onto the peeled PET with a coater. And dried at a temperature of less than 80 ° C., followed by drying at 100 ° C., to obtain a curable soft magnetic sheet having a dried sheet thickness of about 100 μm.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness changed to be thicker after the heat test, but the rate of change was less than 1%. The value of the magnetic permeability μ ′ was 40 or more and the magnetic loss μ ″ was less than 1.5. Also, the glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient were all good. Indicated.

Example 9
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 600 parts by weight, acrylic rubber having glycidyl group (SG80H-3, manufactured by Nagase ChemteX Corp.) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, epoxy A soft magnetic composition comprising 6.7 parts by weight of a latent curing agent for resin (HX3748, manufactured by Asahi Kasei Chemicals Co., Ltd.), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate was applied onto the release PET with a coater. Drying was performed at a temperature of less than 80 ° C., followed by drying at 100 ° C. to obtain a curable soft magnetic sheet having a sheet thickness of about 100 μm after drying.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness was changed to be thicker after the heat test, but the rate of change was less than 2%. The value of the magnetic permeability μ ′ was 38 or more and less than 40 and the magnetic loss μ ″ was less than 1.5. Also, the glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient were all good. Results are shown.

Example 10
As the flat soft magnetic powder, the flat soft magnetic powder Fe-Si-Cr-Ni showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercive force shown in Table 1 A curable soft magnetic sheet having a dried sheet thickness of about 100 μm was obtained by repeating the same operation as in Example 5 except that (made by Zemco Co., Ltd.) was used.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 1. As a result, the sheet thickness was changed to be thicker after the heat test, but the rate of change was less than 2%. The value of the magnetic permeability μ ′ was 40 or more and the magnetic loss μ ″ was less than 1.5. Also, the glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient were all good. Indicated.

Comparative Example 1
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 500 parts by weight, acrylic rubber having no glycidyl group (SG700AS, manufactured by Nagase ChemteX Corporation; weight average molecular weight 350,000, Tg 4.9 ° C.) 75.5 parts by weight, and epoxy resin (Epicoat 1031S, Japan Epoxy Resin) A soft magnetic composition comprising 21 parts by weight of an epoxy resin latent curing agent (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate. , Coated on the peeled PET with a coater, dried at a temperature of less than 80 ° C., subsequently dried at 100 ° C., and a curable soft sheet having a thickness of about 100 μm after drying. To obtain a sexual sheet.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 2. As a result, the sheet thickness after the heat test changed to be thicker, and the rate of change was 2% or more. The value of the magnetic permeability μ ′ was less than 34. The glossiness, tensile strength, electrical resistance, powder fall, and flexibility all showed good results, but the linear expansion coefficient exceeded 22 ppm / ° C.

Comparative Example 2
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 500 parts by weight, butyral resin (BL-1, manufactured by Sekisui Chemical Co., Ltd .; weight average molecular weight 19000, Tg 66 ° C.) 77.1 parts by weight, and blocked isocyanate (Coronate 2507, manufactured by Nippon Polyurethane Co., Ltd.) 25.7 parts by weight And a soft magnetic composition consisting of 390 parts by weight of MEK (methyl ethyl ketone) is coated on the peeled PET with a coater, dried at a temperature of less than 80 ° C., subsequently dried at 115 ° C., and the sheet thickness after drying A curable soft magnetic sheet having a thickness of about 100 μm was obtained.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 2. As a result, the sheet thickness after the heat test changed to be thicker, and the rate of change was 2% or more. In addition, although glossiness, tensile strength, electrical resistance, and powder falling all showed good results, the linear expansion coefficient exceeded 22 ppm / ° C., and the evaluation of flexibility was poor.

Comparative Example 3
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 500 parts by weight, acetal resin (KS-1, manufactured by Sekisui Chemical Co., Ltd .; weight average molecular weight 27000, Tg 107 ° C.) 77.1 parts by weight, and block isocyanate (coronate 2507, manufactured by Nippon Polyurethane Co., Ltd.) 25.7 parts by weight And a soft magnetic composition consisting of 390 parts by weight of MEK is coated on release PET with a coater, dried at a temperature of less than 80 ° C., subsequently dried at 115 ° C., and the sheet thickness after drying is around 100 μm. A curable soft magnetic sheet was obtained.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 2. As a result, the sheet thickness after the heat test changed to be thicker, and the rate of change was 2% or more. The value of the magnetic permeability μ ′ was less than 34. In addition, although glossiness, tensile strength, electrical resistance, and powder falling all showed good results, the linear expansion coefficient exceeded 22 ppm / ° C., and the evaluation of flexibility was poor.

Comparative Example 4
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 400 parts by weight, acrylic rubber having a glycidyl group (SG80H-3, manufactured by Nagase ChemteX Corporation) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, An epoxy resin latent curing agent (HX3748, manufactured by Asahi Kasei Chemicals Co., Ltd.) 6.7 weight, toluene 270 weight, and ethyl acetate 120 weight were coated on release PET with a coater, and 80 Drying was performed at a temperature below 100 ° C., followed by drying at 100 ° C. to obtain a curable soft magnetic sheet having a thickness of about 100 μm after drying.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 2. As a result, the sheet thickness changed to be thicker after the heat test, and the rate of change was 2% or more. The value of the magnetic permeability μ ′ was less than 34. The glossiness, tensile strength, electrical resistance, powder fall, and flexibility all showed good results, but the linear expansion coefficient exceeded 22 ppm / ° C.

Comparative Example 5
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 650 parts by weight, glycidyl group-containing acrylic rubber (SG80H-3, manufactured by Nagase ChemteX Corporation) 80.8 parts by weight, epoxy resin (Epicoat 1031S, manufactured by Japan Epoxy Resin Co., Ltd.) 22.5 parts by weight, A soft magnetic composition composed of 6.7 parts by weight of a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate is applied onto the peeled PET with a coater. And dried at a temperature of less than 80 ° C., followed by drying at 100 ° C., to obtain a curable soft magnetic sheet having a dried sheet thickness of about 100 μm.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 2. As a result, the sheet thickness changed to be thicker after the heat test, and the rate of change was 2% or more. On the other hand, when the amount of the flat soft magnetic powder with respect to the binder exceeded the optimum range, the fluidity was lowered, the orientation state was deteriorated, and the value of the magnetic permeability μ ′ was not increased. Specifically, the value of the magnetic permeability μ ′ was 38 or more and less than 40 and μ ″ was less than 1.5. The tensile strength, electrical resistance, powder fall, and flexibility all showed good results. The linear expansion coefficient was below 15 ppm / ° C., and the glossiness was poorly evaluated.

Comparative Example 6
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 500 parts by weight, nitrile butadiene rubber having no glycidyl group (1072J, manufactured by Nippon Zeon Co., Ltd .; weight average molecular weight 340,000, Tg-24 ° C.) 80.8 parts by weight, epoxy resin (Epicoat 1031S, Japan Epoxy Resin Co., Ltd.) A soft magnetic composition comprising 22.5 parts by weight, a latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight of toluene, and 120 parts by weight of ethyl acetate. Is coated on release PET with a coater, dried at a temperature of less than 80 ° C., then dried at 100 ° C., and a curable soft magnetic sheet having a thickness of about 100 μm after drying. It was obtained over door.

  Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 2. As a result, the sheet thickness changed to be thicker after the heat test, and the rate of change was 2% or more. On the other hand, when the amount of the flat soft magnetic powder with respect to the binder exceeded the optimum range, the fluidity was lowered, the orientation state was deteriorated, and the value of the magnetic permeability μ ′ was not increased. Specifically, the value of magnetic permeability μ ′ was less than 34 and μ ″ was less than 1.5. Although glossiness, tensile strength, electrical resistance, powder fall and flexibility were all good results. The linear expansion coefficient exceeded 22 ppm / ° C.

Comparative Example 7
Flat soft magnetic powder Fe—Si—Cr—Ni (made by Mate Co., Ltd.) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercivity shown in Table 1. 650 parts by weight, acrylic resin having no glycidyl group (WS-023, manufactured by Nagase ChemteX Corporation; weight average molecular weight 500,000, Tg 15 ° C.) 80.8 parts by weight, and epoxy resin (Epicoat 1031S, Japan Epoxy Resin Co., Ltd.) Soft magnetic composition comprising 22.5 parts by weight), latent curing agent for epoxy resin (HX3748, manufactured by Asahi Kasei Chemicals Corporation), 270 parts by weight toluene, and 120 parts by weight ethyl acetate The product is coated on the release PET with a coater, dried at a temperature of less than 80 ° C., subsequently dried at 100 ° C., and a curable soft magnetic sheet having a dried sheet thickness of around 100 μm. To obtain a sheet.

Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 2. As a result, the sheet thickness changed to be thicker after the heat test, and the rate of change was 2% or more. On the other hand, when the amount of the flat soft magnetic powder with respect to the binder exceeded the optimum range, the fluidity was lowered, the orientation state was deteriorated, and the value of the magnetic permeability μ ′ was not increased. Specifically, the value of magnetic permeability μ ′ was less than 34 and μ ″ was less than 1.5. Although glossiness, tensile strength, electrical resistance, powder fall and flexibility were all good results. The linear expansion coefficient exceeded 22 ppm / ° C.

  As can be seen from Table 1, each of the sheet-like soft magnetic materials of Examples 1 to 9 had a small sheet thickness change rate and good magnetic properties even after the heat resistance test. Further, in the case of the sheet-like soft magnetic material of Example 10, since the tap density was small, the sheet thickness change rate was larger than that in Example 5.

  On the other hand, as can be seen from Table 2, in Comparative Examples 1 and 7, the acrylic rubber having no glycidyl group has poor compatibility with the epoxy resin, and the rubber elasticity is large and the compressibility is not sufficient. The thickness change is also large. In the case of Comparative Example 2, since a butyral resin is used, there is no flexibility, and the cured product cannot be processed. In the case of Comparative Example 3, an acetal resin having a high Tg is used. The processability is poor and the thickness change is large. In the case of Comparative Example 4, since the amount of the flat soft magnetic powder is small relative to the binder, the shrinkage of the thickness is increased, and in the case of Comparative Example 5, the orientation of the flat soft magnetic powder is deteriorated. As μ ′ decreases and voids increase, the thickness change increases. Moreover, in the case of the comparative example 6, since the nitrile butadiene rubber is used, a change becomes large as the thickness increases.

Examples 12-18
Other than using the flat soft magnetic powder Fe-Si-Al (Mate Corporation) showing the specific surface area, tap density, 10% particle size, 50% particle size, 90% particle size, flatness and coercive force shown in Table 3. In the case of Examples 12 and 14 to 18, the operation of Example 7 is repeated, and in the case of Example 13, the operation of Example 8 is repeated, whereby the curable soft magnetic sheet having a sheet thickness after drying of around 100 μm is obtained. Got.

Using the obtained curable soft magnetic sheet, a sheet-like soft magnetic material was obtained in the same manner as in Example 1 and evaluated in the same manner as in Example 1. The obtained results are shown in Table 3. As a result, the sheet thickness was changed to be thicker after the heat test, but the rate of change was less than 2%. The glossiness, tensile strength, electrical resistance, powder fall, flexibility, and linear expansion coefficient all showed good results.

  As can be seen from Table 3, each of the sheet-like soft magnetic materials of Examples 12 to 18 using Fe-Si-Al as the soft magnetic powder has a small sheet thickness change rate after the heat resistance test and good magnetic properties. there were.

Example 19
A curable soft magnetic sheet was obtained by repeating the same operation as in Example 15. Prepare four sheets of peeled PET removed from the obtained curable soft magnetic sheet, laminate them, sandwich both sides of the laminate with peeled PET, and buffer 100 μm thick fine paper on both sides A sheet-like soft magnetic material that is placed as a material, sandwiched between two stainless steel (SUS) plates and compressed with a vacuum press (made by Kitagawa Seiki) at a pressure of 24.9 kgf / cm ² for 10 minutes. Got. When the obtained sheet-shaped soft magnetic material was subjected to a heat resistance test (stands in an oven at a temperature of 85 ° C. and a humidity of 60 Rh% for 96 hours), the thickness of the sheet-shaped soft magnetic material after the heat resistance test changed to be thicker. did. Table 4 shows the rate of change.

  From Table 4, it was found that the temperature during pressing is preferably 140 ° C. to 180 ° C. under the conditions of this example.

  The sheet-like soft magnetic material of the present invention is formed from a soft magnetic composition comprising flat soft magnetic powder, acrylic rubber having a glycidyl group, an epoxy resin, a curing agent for epoxy resin, and a solvent. Here, since the acrylic rubber having a glycidyl group reacts with the epoxy resin, the cohesive force of molecules constituting the sheet-like soft magnetic material can be further increased. Moreover, the acrylic rubber and epoxy resin used as a binder are excellent also in heat resistance and moisture resistance. Therefore, the sheet-like soft magnetic material of the present invention can realize good dimensional stability over a long period even in a high temperature and high humidity environment. Moreover, since the flat soft magnetic powder is arranged in the in-plane direction of the sheet-like soft magnetic material, the magnetic characteristics are improved. In addition, since the sheet-like soft magnetic material of the present invention uses acrylic rubber, epoxy resin, and epoxy resin curing agent as a binder, the entire sheet surface has a gloss different from the metallic luster after pressing, and Surface gloss can be maintained for a long time. Therefore, this sheet-like soft magnetic material is useful as a magnetic flux converging body in an RFID system such as a non-contact type IC card or IC tag, or as a general electromagnetic wave absorber. That is, it is useful as a noise electromagnetic wave absorber for electronic devices such as RFID flexible shield materials and portable digital cameras.

Claims (15)

A sheet-like soft magnetic material formed from a soft magnetic composition formed by mixing at least a flat soft magnetic powder, an acrylic rubber, an epoxy resin, an epoxy resin curing agent, and a solvent,
The flat soft magnetic powder is arranged in an in-plane direction of the sheet-like soft magnetic material;
The acrylic rubber has a glycidyl group;
A sheet-like soft magnetic material, wherein the weight ratio of the flat soft magnetic powder to the total amount of acrylic rubber, epoxy resin and epoxy resin curing agent is 3.86 to 5.45 .   The sheet-like soft magnetic material according to claim 1, wherein the flat soft magnetic powder is an Fe-Si-Cr-Ni alloy powder.   The sheet-like soft magnetic material according to claim 1, wherein the flat soft magnetic powder is an Fe-Si-Al alloy powder.   The sheet-like soft magnetic material according to any one of claims 1 to 3, wherein the epoxy resin curing agent exhibits potential. Sheet soft magnetic material according to any one of claims 1-4 the tensile strength is less 50MPa or more 20 Mpa. Sheet soft magnetic material according to any one of claims 1 to 5 gloss at an incident angle of 60 degrees is 50% or less than 20%. The sheet-like soft magnetic material according to any one of claims 1 to 6, wherein the flat soft magnetic powder has a tap density of 0.55 to 1.45 g / ml. 2. The method for producing a sheet-like soft magnetic material according to claim 1, wherein at least a flat soft magnetic powder, an acrylic rubber having a glycidyl group, an epoxy resin, a curing agent for epoxy resin, and a solvent are mixed. A soft magnetic composition is applied onto a release substrate at a temperature at which the curing reaction does not substantially proceed and dried to prepare a curable soft magnetic sheet, and two or more curable soft magnetic sheets are laminated to form a laminate. And a laminate is compressed so as not to be rolled at a temperature at which a curing reaction occurs. The method for producing a sheet-like soft magnetic material according to claim 8, wherein the flat soft magnetic powder has a tap density of 0.55 to 1.45 g / ml. A sheet-like soft magnetic material formed from a soft magnetic composition formed by mixing at least a flat soft magnetic powder, an acrylic rubber, an epoxy resin, an epoxy resin curing agent, and a solvent,
The flat soft magnetic powder is arranged in an in-plane direction of the sheet-like soft magnetic material;
The acrylic rubber has a glycidyl group;
The weight ratio of the flat soft magnetic powder to the total amount of the acrylic rubber, the epoxy resin, and the epoxy resin curing agent is 3.86 to 5.45,
The glossiness at an incident angle of 60 degrees is 20% or more and 50% or less.
A sheet-like soft magnetic material characterized by the above. The sheet-like soft magnetic material according to claim 10, wherein the flat soft magnetic powder is an Fe-Si-Cr-Ni alloy powder. The sheet-like soft magnetic material according to claim 10, wherein the flat soft magnetic powder is an Fe-Si-Al alloy powder. The sheet-like soft magnetic material according to any one of claims 10 to 12, wherein the epoxy resin curing agent exhibits a potential. The sheet-like soft magnetic material according to any one of claims 10 to 13, having a tensile strength of 20 Mpa to 50 MPa. The sheet-like soft magnetic material according to any one of claims 10 to 14, wherein the flat soft magnetic powder has a tap density of 0.55 to 1.45 g / ml.