FERRITE SHEET STRIP, AND ANTENNA DEVICE AND CABLE USING FERRITE SHEET STRIP
20240055167 ยท 2024-02-15
Inventors
- Satoshi OHMAE (Otake-shi, Hiroshima, JP)
- Tetsuya KIMURA (Otake-shi, Hiroshima, JP)
- Makoto SADAI (Otake-shi, Hiroshima, JP)
- Yoji OKANO (Otake-shi, Hiroshima, JP)
Cpc classification
H01Q7/00
ELECTRICITY
H01F1/344
ELECTRICITY
H01Q1/2225
ELECTRICITY
International classification
Abstract
A ferrite sheet strip includes a strip shaped substrate and a plurality of ferrite sheet pieces provided on a surface of the substrate. The plurality of ferrite sheet pieces are aligned and spaced apart by a gap from one another along a longitudinal direction of the substrate. The gap extends at least partially so as not to be parallel to a lateral direction of the substrate.
Claims
1. A ferrite sheet strip comprising: a strip shaped substrate, and a plurality of ferrite sheet pieces provided on a surface of the substrate, wherein the plurality of ferrite sheet pieces are aligned, and spaced apart by a gap from one another, along a longitudinal direction of the substrate, the gap extends at least partially so as not to be parallel to a lateral direction of the substrate.
2. The ferrite sheet strip according to claim 1, wherein the gap has a straight shape.
3. The ferrite sheet strip according to claim 1, wherein the gap has a width of from 0.1 mm to 10 mm.
4. An antenna device comprising: an antenna substrate having a surface including a loop coil formed from a conductive material, and a ferrite sheet laminated on the antenna substrate, wherein the ferrite sheet is configured to be cut from a ferrite sheet strip according to claim 1, the ferrite sheet includes a gap that extends at least partially so as not to be parallel to an extending direction of the loop coil.
5. A cable having an outer perimeter around which a noise filter is wrapped, the noise filter including a ferrite sheet strip according to claim 1.
6. The cable according to claim 5, wherein the ferrite sheet strip according to claim 1 is wrapped around the outer perimeter of the cable continuously in a spiral fashion.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENTS
[0037] Embodiments of the present disclosure will be explained in the following with reference to the drawings. The following description of preferred embodiments is merely an example in nature, and is not intended to limit the present disclosure, application methods of the present disclosure, or use of the present disclosure.
[0038] A ferrite sheet strip according to one embodiment of the present disclosure will be first explained with reference to
[0039] The substrate 10 is a strip shaped thin film, that is, shaped to have the longitudinal direction and a lateral direction. The substrate 10 has a size that is not particularly limited as long as it can be wound in a roll, and, for example, has a length of 50 cm in the lateral direction and a length of 100 m in the longitudinal direction. The substrate 10 includes a material that is not particularly limited, and, for example, can use a resin material, such as polyethylene terephthalate (PET). In
[0040] The sintered ferrite body 21 is a sintered body formed from magnetic ferrite. Types of the ferrite used are not particularly limited as long as it has magnetic properties; however, it can use, for example, NiZn-based ferrite or MnZn-based ferrite. The sintered ferrite body is divided into small pieces. Methods for producing the sintered ferrite body 21 are not particularly limited as well; however, for example, a method for coating a plastic film with a ferrite-dispersed coating liquid can be used. Specifically, the following method can be used.
[0041] First, a coating liquid is prepared by mixing 70 to 120 parts by weight of a polyvinyl alcohol resin, 15 to 25 parts by weight of butyl butylphthalate as a plasticizer, and 400 to 600 parts by weight of a solvent, with 1000 parts by weight of a ferrite powder. For the solvent, for example, glycol ether-based solvents, methyl ethyl ketone (MEK), toluene, methanol, ethanol, and n-butanol can be used. In view of, for example, dispersibility of the ferrite powder and ease of mixing and drying, a blending composition range for the coating liquid is preferably 80 to 110 parts by weight of a polybutyral resin, 18 to 22 parts by weight of butyl butylphthalate, and 450 to 550 parts by weight of a solvent, with respect to 1000 parts by weight of ferrite.
[0042] The coating liquid can be produced by using, but not limited to, a ball mill, for example. When the solvent and ferrite are first loaded and mixed and then the resin and plasticizer are added thereto and mixed, a uniform coating liquid can be obtained. It is important that the obtained coating liquid is sufficiently defoamed under reduced pressure in a vacuum vessel in order to prevent cracks from appearing in a coated film during coating and drying.
[0043] Methods for coating the ferrite-dispersed coating liquid are not particularly limited; however, a roll coater and a doctor blade can be used. Doctor blades may be used as they have film thickness accuracy and stability of the coating liquid. The coating liquid can be coated on a plastic film by means of a doctor blade to form a layer of a desired thickness. The coated layer can be then dried at 80 to 130 C. for 30 to 60 minutes to obtain a molded ferrite sheet.
[0044] The plastic film on which the ferrite-dispersed coating liquid is to be coated is not particularly limited; however, those obtained by sandblasting various films, such as a polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET) and polyimide film, can be used. A polyethylene terephthalate (PET) film is preferable for its processability of a film surface and thermal stability during coating and drying. When a sandblasted plastic film is used, the unevenness of the plastic film can be transferred to the molded ferrite sheet to thereby obtain the molded sheet having a desired surface roughness.
[0045] Next, the obtained molded ferrite sheet is heat-treated to obtain the sintered ferrite body 21. The heat treatment is performed such that, for example, as many as 5 to 20 molded ferrite sheets are stacked on an alumina plate having a porosity of 30%. Regarding heat treatment conditions, it is important to provide processes for removal of resin components and growth of ferrite particles by using an electric furnace or the like. The removal of resin components is performed in conditions that are at 150 C. to 550 C. for 5 to 80 hours, and the growth of ferrite particles is performed in conditions that are 850 C. to 1200 C. for 1 to 5 hours. To prevent thermal deformation and cracking of the sheets, the removal of resin components may be performed at a temperature that is raised from room temperature at a rate of as much as 10 to 20 C./hour and then maintained constant. It is also preferred that the temperature is then raised at a rate of 30 to 60 C./hour, maintained constant to sufficiently sinter and grow the ferrite particles, and then gradually decreased. In this regard, optimum conditions for the retention time and temperature in each process may be selected according to the number of the molded ferrite sheets to be treated. The sintered ferrite body 21 can be obtained in the processes as described above. Thereafter, a double coated tape serving as the adhesive materials 22, 23 is then provided on the top and bottom surfaces, and the sintered ferrite body 21 is divided by, for example, a roller to form ferrite sheet pieces 20. Predetermined grooves may be formed in the molded ferrite sheet to divide the sintered ferrite body 21 into small pieces. The grooves may be either continuous or intermittent, and may be substituted by forming many fine recesses. The sintered body is divided into triangular, quadrilateral, polygonal shapes of any size, or shapes combining thereof, by using the preformed grooves. The sintered body may also be divided into irregular shapes without the grooves formed.
[0046] As described above, the gap 30 is provided between the plurality of ferrite sheep pieces 20 and extends at least partially so as not to be parallel to the lateral direction of the substrate 10. Specifically, in the embodiment, the gap 30 is a straight gap extending along a direction oblique to the lateral direction of the substrate 10. The gap 30, however, is not limited to this configuration, and may be a curved shape, a polygonal line shape, a corrugated shape, and a zigzag shape, for example. The gap 30 having an excessively small width is not preferable as an overlap between the ferrite sheet pieces 20 may occur, and nor is the gap 30 having an excessively large width preferable as the gap 30 has a greater influence on communication ranges of an antenna when the ferrite sheet strip 1 is applied to an antenna device. Thus, the gap 30 preferably has a width of from 0.1 mm to 10 mm. The width of the gap 30 refers herein to a shortest distance between one ferrite sheep piece 20 and a ferrite sheet piece 20 adjacent thereto.
[0047] Next, an antenna device according to one embodiment of the present disclosure which uses the ferrite sheet strip 1 described above will be explained with reference to
[0048] Specifically, the antenna device 40 includes an adhesive material 22, a sintered ferrite body 21, an adhesive material 23, the antenna substrate 42, and the loop coil 41 in the order from the lower layer. In this respect, the antenna device 40 includes other components, such as a capacitor, required for functioning as an antenna, which are neither explained nor shown herein. The antenna device 40 is configured to adhere to, for example, a metal card via the adhesive material 22 to use as an IC card by undergoing certain processes. The sintered ferrite body 21 of the antenna device 40 also includes a gap 30. As described above, the gap 30 is formed as a straight shape to extend along a direction oblique to the lateral direction of the substrate 10, and thus also extends along a direction oblique to the lateral direction of the antenna device 40. The gap 30 therefore extends to intersect the loop coil 41. The antenna device may also be affixed to a metal housing for use.
[0049] The antenna substrate 42 is formed from an insulating resin material, such as PET, and the loop coil 41 is formed from a conductive material, such as a metal. Methods for forming the loop coil 41 are not particularly limited; however, it can be formed by coating or printing of a conductive material paste, for example.
[0050] Next, one example of a method for applying the ferrite sheet strip 1 according to the embodiment to an antenna device will be explained with reference to
[0051] As shown in
[0052] As described above, when the cutting is made between the plurality of loop coils 41, the gap 30 is positioned differently in each of the cut antenna devices 40 since the distance between the gaps provided between the loop coils 41 does not necessarily correspond to the distance between the gaps 30 provided in the ferrite sheet strip 1. That is, in the antenna device 40 as shown in
[0053] Such gap 30 may affect resonance frequency of the antenna device 40. In this respect, as explained in Examples below in detail, while the gap 30 significantly worsens the resonance frequency of the antenna device when the gap 30 extends to overlap along a coil wire of the loop coil 41 (extends parallel over the coil wire of the loop coil 41), the gap 30 does not significantly affect the resonance frequency of the antenna device 40 when the gap 30 does not extend to overlap along the coil wire of the loop coil 41 and simply intersects the coil wire of the loop coil 41. In the antenna device 40 according to the embodiment, as described above, since the gap 30 is formed as a straight shape to extend along the direction oblique to the lateral direction of the antenna device 40, the gap 30 thus does not extend to overlap along the coil wire of the loop coil 41 and only simply intersects the coil wire of the loop coil 41. Therefore, the antenna device 40 according to the embodiment has the gap 30, which however does not significantly affect the resonance frequency.
[0054] Even a gap having, for example, a curved shape, a polygonal line shape, a corrugated shape, and a zigzag shape as described above as an example, other than the gap 30 having a straight shape to extend along the direction oblique to the lateral direction of the antenna device 40 as in the embodiment, does not extend to overlap along the coil wire of the loop coil 41 and only simply intersects the coil wire of the loop coil 41. Even when the antenna device has the gap of such shape, the gap thus does not significantly affect the resonance frequency.
[0055] As described above, the ferrite sheet strip according to the embodiment can be wound in a roll, and can be suitably applied to the antenna device while enabling reduction in variations in the resonance frequency of the antenna device and reduction of worsening of the communication ranges. The antenna device according to the embodiment then can reduce variations in the resonance frequency of the antenna device and reduce worsening of the communication ranges while making use of the ferrite sheet strip.
[0056] Next, a method for applying the ferrite sheet strip 1 according to the embodiment to a cable will be explained. In the embodiment, a noise filter is wrapped around an outer perimeter of the cable, and the ferrite sheet strip 1 is used as the noise filter. As described above, it is previously known that a ferrite sheet can be used as a noise filter for reducing electromagnetic wave noise generated in a cable. In the embodiment, the ferrite sheet strip 1 is wrapped around the outer perimeter of the cable to reduce the electromagnetic wave noise generated in the cable. Methods for wrapping the ferrite sheet strip 1 around the outer perimeter of the cable are not particularly limited; however, it is preferable in view of workability to wrap the ferrite sheet strip 1 around continuously in a spiral fashion along a direction of an axis of the cable.
EXAMPLES
[0057] Examples are presented below for explaining in detail a ferrite sheet strip according to the present disclosure and an antenna device using the ferrite sheet strip. In Examples, experiments are conducted for influence of a gap of the ferrite sheet on resonance frequency of the antenna device.
Example 1
[0058] First, in Example 1, an experiment is conducted for a relationship between a position and width of the gap and resonance frequency of the antenna device when the gap provided in the ferrite sheet extends parallel to the lateral direction of the antenna device.
Experiment Example 1
[0059] Changes in the position and width of the gap and the resonance frequency of the antenna device were first investigated through simulations using Electromagnetic simulation EMpro (Keysight Technologies). A model of the antenna device was produced to place a ferrite sheet having a thickness of 0.045 mm on a metal plate having a thickness of 0.2 mm via 0.01 mm spacing, and place a loop coil having a thickness of 0.02 mm thereon via 0.01 mm spacing. The metal plate had a rectangular shape with an 80 mm long side and 50 mm short side. The ferrite sheet had the same size as the metal plate. The loop coil had an outermost circumferential length on the long side being 75 mm and an outermost circumferential length on the short side being 45 mm.
[0060] As shown in
[0061] As shown in
Experiment Example 2
[0062] Next, changes in the position and width of the gap and the resonance frequency of the antenna device were investigated by actual measurements using actual antenna devices to demonstrate the results of the experiment example 1. The antenna devices had the same size as the model in the experiment example 1. The gap was provided in the positions shown in
[0063] As shown in
[0064] In the results of Example 1 as described above, it is found that the resonance frequency of the antenna device is significantly affected when the gap in the ferrite sheet extends parallel over the coil wire along an extending direction of the coil wire, and it is thereby considered that communication ranges of the antenna device are reduced.
Example 2
[0065] Next, in Example 2, an experiment is conducted for a relationship between a position and width of the gap and resonance frequency of the antenna device when the gap provided in the ferrite sheet extends obliquely to, that is, extends along a diagonal direction with respect to, the lateral direction of the antenna device.
Experiment Example 1
[0066] Changes in the position and width of the gap and the resonance frequency of the antenna device were first investigated through simulations using Electromagnetic simulation EMpro (Keysight Technologies). A model of the antenna device was produced to place a ferrite sheet having a thickness of 0.045 mm on a metal plate having a thickness of 0.2 mm via 0.01 mm spacing, and place a loop coil having a thickness of 0.02 mm thereon via 0.01 mm spacing. The metal plate had a rectangular shape with an 80 mm long side and 50 mm short side. The ferrite sheet had the same size as the metal plate. The loop coil had an outermost circumferential length on the long side being 75 mm and an outermost circumferential length on the short side being 45 mm.
[0067] As shown in
[0068] As shown in
Experiment Example 2
[0069] Next, changes in the position and width of the gap and the resonance frequency of the antenna device were investigated by actual measurements using actual antenna devices to demonstrate the results of the experiment example 1. The antenna devices had the same size as the model in the experiment example 1. The gap was provided in the positions shown in
[0070] As shown in
[0071] In the results of Example 2, the variations as compared to the resonance frequency in the case where no gap is provided are smaller when the gap provided in the ferrite sheet extends obliquely to the lateral direction of the antenna device, and it can thus be said that no significant influence is produced on the communication ranges of the antenna device.
[0072] In the results of Examples 1 and 2 as described above, while the gap 30 is considered to significantly affect the resonance frequency of the antenna device to significantly worsen the communication ranges when the gap 30 extends to overlap along the coil wire of the loop coil 41 (extends parallel over the coil wire of the loop coil 41), the gap 30 is considered to have a smaller influence on the resonance frequency of the antenna device 40 and thereby not to significantly affect the communication ranges when the gap 30 does not extend to overlap along the coil wire of the loop coil 41 and simply intersects the coil wire of the loop coil 41.
[0073] As described in the results, even when the gap is a straight shape to extend along the lateral direction of the antenna device, no significant variations in the resonance frequency of the antenna device are generated in the case where the gap is provided in the central portion of the antenna device and does not extend to overlap along the coil wire. However, as described above, some antenna devices will be manufactured with the gap extending to overlap along the coil wire, as the gap in the antenna device is positioned differently in each of the antenna devices when the ferrite sheet strip and the strip shaped antenna substrate are used. Another alignment process is required to ensure that the gap is not located over the coil wire, resulting in inconvenience. On the other hand, when the gap extends obliquely to the lateral direction of the antenna device as in Example 2, no gap extends to overlap along the coil wire even if the gap is located at any position in the antenna device. This ensures that the variations in the resonance frequency of the antenna device due to the gap can be reduced without a need of, for example, the alignment process to avoid reduction in the communication ranges.
[0074] As described above, the ferrite sheet strip according to the present disclosure can be wound in a roll, and can be suitably applied to the antenna device while enabling reduction in variations in the resonance frequency of the antenna device and reduction of worsening of the communication ranges. The antenna device according to the present disclosure then can reduce variations in the resonance frequency of the antenna device and reduce worsening of the communication ranges while making use of the ferrite sheet strip, and thus significantly useful.
DESCRIPTION OF REFERENCE CHARACTERS
[0075] 1 Ferrite sheet strip [0076] 2 Ferrite sheet (after cutting) [0077] 10 Substrate [0078] 20 Ferrite sheet piece [0079] 21 Sintered ferrite body [0080] 22, 23 Adhesive material [0081] 30 Gap [0082] 40 Antenna device [0083] 41 Loop coil [0084] 42 Antenna substrate