Shielding film and method for producing a shielding film
11723182 · 2023-08-08
Assignee
Inventors
Cpc classification
H05K9/0088
ELECTRICITY
International classification
Abstract
A method for manufacturing a shielding film is provided. The method includes providing a band of an amorphous soft magnetic alloy; thermally treating the band at a temperature of 500° C. to 600° C. for 1 minute to 1 hour under an N2- or H2-containing atmosphere and under the Earth's magnetic field, thereby creating a nanocrystalline soft magnetic band with a round hysteresis loop; applying an adhesive layer to at least one side of the band; and wherein the band is first applied to a substrate, then thermally treated, after which an adhesive film is applied to the band and, finally, the band is structured by breaking.
Claims
1. A method for manufacturing a shielding film, comprising the following steps: providing a band of an amorphous soft magnetic alloy; wrapping the band into a coil on a substrate; thermally treating the band in the form of the coil at a temperature of 500° C. to 600° C. for 1 minute to 1 hour under an N.sub.2— or H.sub.2-containing atmosphere and under the Earth's magnetic field, thereby creating a nanocrystalline soft magnetic band with a round hysteresis loop; applying an adhesive layer to at least one side of the nanocrystalline soft magnetic band by a reel-to-reel process; and wherein the band is structured by breaking after applying the adhesive layer.
2. The method of claim 1, wherein a one-sided or double-sided adhesive film, heat-sealable film or powdered hot adhesive is used as the adhesive layer.
3. The method of claim 1, wherein the thermal treatment is done in a continuous pass.
4. The method of claim 1, wherein the band is cut mechanically into several strips.
5. The method of claim 1, wherein the band is cut mechanically with rolling scissors into several strips.
6. The method of claim 1, wherein the band is pulled under tensile force over a sharp edge in order to divide the band into several parts.
7. The method of claim 1, wherein shielding parts are punched or cut from the band with a nanocrystalline alloy.
8. The method of claim 1, wherein the soft magnetic alloy consists of a composition of Fe.sub.100-a-b-c-x-y-zCu.sub.aM.sub.bT.sub.cSi.sub.xZ.sub.z and up to 0.5 atom % contaminants, where M is one or more of the group consisting of Nb, Mo and Ta, T is one or more elements selected from the group consisting of V, Cr, Co and Ni; and Z is one or more elements selected from the group consisting of C, P and Ge; and wherein 0.5 atom %<a<1.5 atom %, 2 atom %<b<4 atom %, 0 atom %<c<5 atom %, 12 atom %<x<18 atom %, 5 atom %<y<12 atom % and 0 atom %<z<2 atom %.
9. The method of claim 8, wherein the nanocrystalline soft magnetic alloy is Fe.sub.73.8Nb.sub.3Cu.sub.1Si.sub.15.6B.sub.6.6.
10. The method of claim 1, wherein the nanocrystalline soft magnetic alloy has a hysteresis loop with a ratio of remanence induction, B.sub.r, over saturation induction, B.sub.s, B.sub.r/B.sub.s, in the closed magnetic circuit from 30% to 100%.
11. The method of claim 1, wherein the nanocrystalline soft magnetic alloy has a frequency-dependent permeability μ=μ′+iμ″ and a quality factor Q(f)=μ′+μ″, such that the maximum quality factor Q.sub.max is >22.
12. A method for manufacturing a shielding film, comprising the following steps: providing a band of an amorphous soft magnetic alloy; thermally treating the band in a continuous process at a temperature of 500° C. to 600° C. for 1 minute to 1 hour under an N.sub.2— or H.sub.2-containing atmosphere and under the Earth's magnetic field, thereby creating a nanocrystalline soft magnetic band with a round hysteresis loop; applying an adhesive layer to at least one side of the nanocrystalline soft magnetic band by a reel-to-reel process; and structuring the band by breaking after applying the adhesive layer.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) Exemplary embodiments and certain examples will now be explained in further detail with reference to the drawings and table.
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DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
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(19) The first part 11 is connected to a power source, for example via a cable and plug. The power that is transmitted wirelessly from the transmitter coil 12 of the first part 11 to the receiver coil 15 in the separate device 13 is used there to charge a battery or accumulator (not shown).
(20) The mobile device 13 has a shielding film 15 that shields against the penetration of the magnetic field into the device 13 or into electronic components of the device 13. The shielding film can be arranged on the interior of the device 13 and/or between the coil and the battery to be charged. Two or more shielding films can be integrated into the device 13. One or more shielding films 15 can also be integrated into the first part 11.
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(22) The layer 20 has several strips 22 of a nanocrystalline soft magnetic alloy. In this exemplary embodiment, this alloy is an iron-based alloy and particularly Fe.sub.73.8Nb.sub.3Cu.sub.1Si.sub.15.6Si.sub.15.6B.sub.6.6. The strips 22 are arranged parallel to one another and on an adhesive layer 24, which is a one-sided adhesive film in this exemplary embodiment. The adhesive film acts as a substrate for the strips 22. The strips 22 are arranged on a plane and separated from one another by gaps 26 that are bridged over by the adhesive layer 24.
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(25) A plurality of strips 44 are arranged on this adhesive film 45. A second adhesive layer 46 is arranged on the upper sides 47 of the strips 44.
(26) The second layer 42 has a plurality of strips 44′ that are also arranged parallel to each other on a plane. The strips are arranged on the second adhesive layer 46 of the first layer 41, the strips 44′ of the second layer 42 being offset laterally in relation to the strips 44 of the first layer 41, so that an area of the strip 44′ of the second layer 42 covers the gaps between the strips 44 of the first layer 41. The second layer 42 also has an adhesive layer 46, which is arranged on the upper sides 47 of the strips 44′.
(27) Like the other two layers 41, 42, the third layer 43 of the shielding film 40 has a plurality of parallel strips 44″ on whose upper side 47 an adhesive layer 48 is arranged. The strips 44″ of the third layer 43 are arranged on the adhesive layer 46 of the second layer 42, so that the strips 44″ of the third layer 43 are offset laterally in relation to the strips 44′ of the second layer 42. The strips 44″ of the third layer 43 are not offset laterally in relation to the strips 44 of the first layer 42. The strips 44, 44′, 44″ of the three layers 41, 42, 43 run parallel to each other. A second outer adhesive film 49 is arranged on the adhesive layer 48 of the third layer 43, so that the strips 44, 44′, 44″ of the three layers 41, 42, 43 are arranged between two adhesive films 45, 49.
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(30) To increase the shielding performance, the soft magnetic alloy should have the following characteristics: a high permeability, as little loss as possible in the frequency range >100 kHz, and as high a quality factor as possible in the frequency range >100 kHz.
(31) Below, quality measurements performed on planar inductors are described. On the basis of the exemplary embodiments, selections can be made in terms of material, band thickness, heat treatment method and structuring. The heat treatment of the specimens was performed on a stack of about 50 individual parts. For the examples, the VITROVAC® alloys VC 6025 I50, VC 6155 U55 with the composition Fe.sub.69.5Nb.sub.3.5Mo.sub.3Si.sub.16B.sub.7 and Co.sub.72.7Fe.sub.4.8Si.sub.5.5B.sub.17, respectively, and the VITROPERM® alloy VP 800 with the composition Fe.sub.73.8Nb.sub.3Cu.sub.1Si.sub.15.6B.sub.6.6 were used.
(32) The material quality measurements were carried out with the aid of a planar coil and an LC measuring bridge. The square or round specimens were placed at a minimal distance (e.g., about 0.2 to 0.3 mm) to one side of the planar coil. All of the results shown subsequently relate to a single material layer. Depending on the application, however, a shielding film or a shielding part can have several soft magnetic layers.
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Q(f)=μ′/μ″
and since the cycle losses due to eddy currents are determined only from the imaginary part of the permeability, a high quality factor is obtained in those frequency ranges in which the material losses are small.
(36) The influence of the alloy system on the quality was examined.
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(38) The material parameters, the heat treatment status and the maximum achievable quality values are summarized in table 1 for the illustrated examples. By comparing the maximum achievable quality values, one can see that higher quality values can be achieved with Fe-based alloys in the nanocrystalline state.
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(41) The eddy current losses are reduced with increasing material thickness. Accordingly, the highest quality values are achieved in the smallest band thicknesses, as can be seen from
(42) The influence of the heat treatment with and without magnetic field on the quality was investigated.
(43) Heat treatment of the materials cited above can be performed with and without the application of magnetic fields. Through the application of magnetic fields during a heat treatment, aligned anisotropes can be introduced into soft magnetic specimens. A heat treatment without a magnetic field yields specimens with round hysteresis loops having only a very small residual anisotropy. These samples are designated by the letter “X.”
(44) If a magnetic field is applied during heat treatment transverse to the band longitudinal direction, a transverse anisotropy is obtained in the specimen, which leads, when measured in the band direction, to a “flat” hysteresis loop that is designated by the letter “F.”
(45) Likewise, it is possible to apply the magnetic field parallel to the band longitudinal direction during the heat treatment. In that case, one obtains a longitudinal anisotropy in the specimen, which leads, when measured in the band direction, to a “Z-shaped” hysteresis loop. These samples are designated by the letter “Z.”
(46) One would now expect for specimens with “flat” hysteresis loops to exhibit good quality, since toroidal cores with “flat” hysteresis loops have less loss. It can be seen from
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(48) Toroidal cores with “Z-shaped” hysteresis loops exhibit high losses. Due to the mixed state, planar specimens with an “F” or “Z” heat treatment are therefore more prone to losses and thus exhibit lower quality. In the case of square specimens (here 20.3×20.3 mm) that are used in a radially symmetrical coil arrangement (see
(49) As shown in the exemplary embodiment in table 1, the best quality factors are obtained for nanocrystalline Fe-based alloys such as VITROPERM® 800 after heat treatment on a “round” hysteresis loop.
(50) The influence of a coating with adhesive film on the quality was examined.
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(52) The influence of the coating of nanocrystalline VITROPERM® 800 specimens with adhesive band on the quality is low. Indeed, measurements of the quality profile on coated and uncoated specimens yielded very similar values, as can be seen from
(53) The influence of the inner structuring on the quality was also investigated.
(54) Another increase in quality with nanocrystalline VITROPERM® 800 with “round” hysteresis loop was also achieved through inner structuring. For this purpose, narrow slits were introduced in the material plane.
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(56) The material parameters, the heat treatment status and the quality values achieved for the individual structures are summarized in table 1.
(57) To produce single-layer or multilayer shielding films or shielding parts with high quality from a nanocrystalline, soft magnetic Fe-based alloy (VITROPERM® 800), one of the following production methods can be used.
(58) 1.) Heat Treatment on the Coil=>Film Composite=>Structure=>Shielding Film or Shielding Part
(59) Using this production method, the individual processes can be carried out very cost-effectively. The starting point is represented by a directly cast or cut VITROPERM® band of any width wrapped into coils on special substrates. The coils are then heat-treated on a “round” hysteresis loop at 575° C. and under N.sub.2 or H.sub.2 atmosphere, the material being brought to the nanocrystalline state. The brittle band is now coated with an adhesive band in a “reel-to-reel,” i.e., coil-to-coil process in order to ensure workability for ensuing steps. For a multilayer film composite (several layers of VITROPERM®), the reel-to-reel process must be carried out several times with double-sided adhesive band. By virtue of the coating with adhesive band, the otherwise brittle band material can now be subjected to additional processing steps. Shielding parts can then be manufactured directly by cutting or punching.
(60) For shielding material that meets higher quality demands, internal structuring can be performed. The single-layer or multilayer film composite is now cut on rolling scissors into narrow strips (0.5 to 10 mm). A device is used to bring the individual strips together again on another substrate adhesive band with mutual spacing of <0.2 mm, thus resulting in a film composite as shown in
(61) For a multilayer, structured construction with offset stacking, single-layer composite films can be cut into narrow strips and brought together again. The resulting structured films can then be brought together in an offset manner as shown in
(62) 2.) Part=>Structure=>Heat Treatment on the Part=>Film Composite=>Shielding Part
(63) The production process described under 1.) provides for the mechanical processing of the material after heat treatment in a “reel-to-reel” process in which the individual shielding part is created only at the end of the production chain. In contrast to that, the heat treatment can be performed on parts that have already been prefabricated, stacked packets and structured stacked packets.
(64) For this purpose, directly cast or cut VITROPERM® band of any width is processed. The manufacture of individual parts could be done on rolling scissors, automatic cutting machines or punches. This is followed by the heat treatment of the individual parts on a “round” hysteresis loop at 575° C. and under N.sub.2 or H.sub.2 atmosphere, the material being brought into the nanocrystalline state. The brittle individual parts are then coated or brought together into packets stacked in a structured manner, all of the possibilities described under 1.) being possible. A flexible shielding part is obtained by coating the heat-treated parts, the stacked packets or the structure-stacked packets with adhesive film. This adhesive film should preferably be present as a long substrate film in order to enable a subsequent reel-to-reel process.
(65) 3.) Woven Fabric of VITROPERM® Bands=>Heat Treatment=>Film Composite=>Shielding Film
(66) The starting point is represented here by a woven fabric, e.g., tube weave, of narrowly cut VITROPERM® band (see
(67) For a multilayer film composite, the reel-to-reel process can be carried out several times with double-sided adhesive band. This method has the advantage that the inner structuring is already present in the form of the weave, whereby the losses are again greatly reduced and resulting here, too, in shielding material of high quality.
(68) 4.) Heat Treatment on the Coil=>Film Composite=>Structure Through Breaking=>Shielding Film
(69) The starting point is represented by a directly cast or cut VITROPERM® band wrapped into coils on special substrates. The coils are then heat-treated on a “round” hysteresis loop at 575° C. and under N.sub.2 or H.sub.2 atmosphere, the material being brought to the nanocrystalline state. The brittle band is now coated on both sides with an adhesive band in a “reel-to-reel” process. To increase the quality, another procedure for inner structuring is proposed here. In the described reel-to-reel process, the film composite must be pulled under tensile force over a sharp metal edge in order to break the brittle VITROPERM® band located between the films into small parts. Here, too, the eddy currents on the material plane are spatially limited, the losses are reduced and the quality factor is increased.
(70) Further processing into multilayer shielding films or parts would be possible in a manner analogous to that described under 1.).
(71) Instead of the abovementioned commercially available one-sided or double-sided adhesive films, which are necessary for fixing the layers of magnetic material or to achieve inner structuring, other adhesive technologies such as heat-sealable films, powdered hot adhesives or the like can be used.
(72) TABLE-US-00001 TABLE 1 Js Thickness Inner Quality Frequency at No. Material [T] d [μm] Heat treatment.sup.2 structure Q.sub.max[ ] Q.sub.wax f [kHz] 1 VC 6155 U55 0.99 23 F, Z, amorphous none 11.5 70 2 VC 6025 I50 0.55 34 F, Z, amorphous none 11.0 80 3 VC 6025 I50 0.55 27 F, Z, amorphous none 12.3 90 4 VC 6025 I50 0.55 23 F, Z, amorphous none 12.9 100 5 VC 6025 I50 0.55 20 F, Z, amorphous none 13.6 106 6 VC 6025 I50 0.55 15 F, Z, amorphous none 14.2 112 7 VC 6025 I50 0.55 27 X, amorphous none 17.5 100 8 VC 6025 I50 0.55 15 X, amorphous none 22.2 130 9 VC 6025 I50 + 0.55 27 X, amorphous none 29.9 130 KF.sup.3) 10 VP 800 1.21 17 F, Z, nano none 15.8 100 11 VP 800 1.21 25 X, nano none 26.2 170 12 VP 800 1.21 17 X, nano none 35.5 350 13 VP 800 + KF.sup.3) 1.21 17 X, nano none 35.9 360 14 VP 800 + KF.sup.3) 1.21 17 X, nano 10.2 mm 41.1 410 0.2 mm 15 VP 800 + KF.sup.3) 1.21 17 X, nano 5.1 mm 49.2 510 0.2 mm 1 VP 800 + KF.sup.3) 1.21 17 X, nano 2.5 mm 54.2 630 0.2 mm 1 VP 800 + KF.sup.3) 1.21 17 X, nano 1.3 mm 59.2 770 0.2 mm
(73) Numbers 1 to 7 and 10 show comparative examples for the related art, while numbers 8, 9 and 11 to 17 show examples according to an embodiment of the invention.
(74) Terms used in the table: 1) J.sub.s: saturation polarization 2) Heat treatment: X—Heat treatment without magnetic field F—Heat treatment in the magnetic transverse field with the result of anisotropy transverse to the band longitudinal direction Z—Heat treatment in the magnetic longitudinal field with the result of anisotropy along the band longitudinal direction Amorphous—After treatment, the specimen is present in the amorphous state Nano—After treatment, the specimen is present in the nanocrystalline state and 3) KF: Laminated with adhesive film