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WO2014088954A1 - Feuille crue en ferrite, feuille en ferrite frittée, feuille composite en ferrite les comprenant, et module à antenne cadre conductrice - Google Patents

Feuille crue en ferrite, feuille en ferrite frittée, feuille composite en ferrite les comprenant, et module à antenne cadre conductrice Download PDF

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Publication number
WO2014088954A1
WO2014088954A1 PCT/US2013/072634 US2013072634W WO2014088954A1 WO 2014088954 A1 WO2014088954 A1 WO 2014088954A1 US 2013072634 W US2013072634 W US 2013072634W WO 2014088954 A1 WO2014088954 A1 WO 2014088954A1
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WO
WIPO (PCT)
Prior art keywords
ferrite
sheet
pattern
sintered
green sheet
Prior art date
Application number
PCT/US2013/072634
Other languages
English (en)
Inventor
Eun-Kwang Hur
Jung-Ju Suh
Seung-Ah CHO
Suk-Won Choi
Original Assignee
3M Innovative Properties Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from KR1020130083828A external-priority patent/KR101476044B1/ko
Application filed by 3M Innovative Properties Company filed Critical 3M Innovative Properties Company
Priority to CN201380063914.6A priority Critical patent/CN104885166B/zh
Priority to US14/649,568 priority patent/US9847577B2/en
Priority to JP2015546536A priority patent/JP6509123B2/ja
Publication of WO2014088954A1 publication Critical patent/WO2014088954A1/fr

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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
    • C—CHEMISTRY; METALLURGY
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62625—Wet mixtures
    • C04B35/62635—Mixing details
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    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/008—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/34—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials non-metallic substances, e.g. ferrites
    • H01F1/342—Oxides
    • H01F1/344—Ferrites, e.g. having a cubic spinel structure (X2+O)(Y23+O3), e.g. magnetite Fe3O4
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3241—Chromium oxides, chromates, or oxide-forming salts thereof
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/327—Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3275—Cobalt oxides, cobaltates or cobaltites or oxide forming salts thereof, e.g. bismuth cobaltate, zinc cobaltite
    • C04B2235/3277—Co3O4
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/327—Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3281—Copper oxides, cuprates or oxide-forming salts thereof, e.g. CuO or Cu2O
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3284—Zinc oxides, zincates, cadmium oxides, cadmiates, mercury oxides, mercurates or oxide forming salts thereof
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3298—Bismuth oxides, bismuthates or oxide forming salts thereof, e.g. zinc bismuthate
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5445—Particle size related information expressed by the size of the particles or aggregates thereof submicron sized, i.e. from 0,1 to 1 micron
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602—Making the green bodies or pre-forms by moulding
    • C04B2235/6025—Tape casting, e.g. with a doctor blade
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/76—Crystal structural characteristics, e.g. symmetry
    • C04B2235/762—Cubic symmetry, e.g. beta-SiC
    • C04B2235/763—Spinel structure AB2O4
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/94—Products characterised by their shape
    • C04B2235/945—Products containing grooves, cuts, recesses or protusions
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
    • C04B2235/9615—Linear firing shrinkage
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q7/00—Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop
    • H01Q7/06—Loop antennas with a substantially uniform current distribution around the loop and having a directional radiation pattern in a plane perpendicular to the plane of the loop with core of ferromagnetic material

Definitions

  • the present invention relates to a ferrite green sheet used to manufacture a ferrite composite sheet configured to isolate a metal substrate from a radio-frequency identification (RFID) antenna or a near field communication (NFC) antenna, a sintered ferrite sheet, a ferrite composite sheet including the same, and a conductive loop antenna module.
  • RFID radio-frequency identification
  • NFC near field communication
  • RFID refers to technology of reading information stored in an electronic tag in a non-contact mode wherein the reading of the information is performed through an antenna or a reader using radio waves.
  • a transportation card may be considered to be an electronic tag, and a transportation card terminal may be considered to be a reader.
  • NFC refers to communication technology of exchanging various kinds of wireless data within a short distance of 10 cm. This technology is non-contact short-range wireless communication technology using a frequency band of 13.56 MHz.
  • the NFC technology has been widely used for handling of information on articles in a supermarket or store, transfer of tourist information for visitors, traffic, and locking devices for access control, as well as for payment, and has a short-range communication distance. As a result, the NFC technology has attracted attention since it has relatively superior security and is inexpensive.
  • an NFC/RFID loop antenna is installed in this space.
  • the flow of an electric current results in formation of a magnetic field, which is then allowed to transfer signals to other sides.
  • the product is configured so that an antenna having a coil mounted therein can be installed in the product to enable the exchange of data stored in the product.
  • the antenna is installed in a battery or a printed circuit board (PCB) so that it is positioned adjacent to a conductive material such as a metal, the antenna reacts with the metal and causes interference, preventing generation of signals.
  • PCB printed circuit board
  • the problems regarding such interference can be effectively solved by isolating magnetism using a material exhibiting high permeability and having low permeability loss.
  • the material exhibiting high permeability allows signals to travel toward a magnetic material rather than the metal to prevent the interference of the metal.
  • a material is generally referred to as an isolator.
  • ferrite is known as a material exhibiting high permeability and having low permeability loss as described above. Also, various methods of manufacturing a ferrite sheet are already known in the related art.
  • Ferrite sheets used recently have grooves that cross continuously in a certain pattern mode, and the grooves can be compartmentalized by the patterns designed thus. Therefore, the ferrite sheet can be easily handled, and attached to a flat or curved plane.
  • US 2012/0088070 A l discloses a composite ferrite sheet having V-shaped grooves arranged in a lattice-type mode, a method of manufacturing a composite ferrite sheet, and a sintered ferrite segment used to form the composite ferrite sheet.
  • Korean Patent Publication No. 10-2008-0082466 discloses a ferrite molded sheet having controlled surface roughness, a sintered ferrite substrate, and an antenna module. All the prior-art documents encounter difficulties in forming precise patterns since the patterns are formed by mechanically applying a pressure onto a green sheet using a knife or drum.
  • An object of the present invention is to provide a novel ferrite green sheet and a sintered ferrite sheet on which burrs or particles are not formed after molding, a ferrite composite sheet including the same, and an antenna module.
  • a ferrite green sheet having a pattern formed at a top surface thereof wherein the pattern includes a plurality of grooves, and each of the grooves has a round-shaped bottom, which has a radius of curvature R, and a width W.
  • a ratio (W:R) of W to R is in a range of 1 :0. 1 to 1 :0.5.
  • a sintered ferrite sheet having a pattern formed at a top surface thereof wherein the pattern includes a plurality of grooves, and each of the grooves has a round-shaped bottom, which has a radius of curvature R, and a width W.
  • a ratio (W:R) of W to R is in a range of 1 :0. 1 to 1 :0.5.
  • a ferrite composite sheet including the sintered ferrite sheet.
  • a conductive loop antenna module including a magnetic member including the sintered ferrite sheet, a conductive loop antenna installed at one surface of the magnetic member, and a conductive layer installed opposite to the surface of the magnetic member having the conductive loop antenna formed therein.
  • the conductive loop antenna module is used in wireless communication media and wireless communication medium processing apparatuses.
  • a novel ferrite green sheet in which burrs are not formed and particles do not break off can be provided.
  • the ferrite sheet according to the present invention can be manufactured with high productivity without causing a bottleneck state during a process since the grooves are formed by tape casting.
  • the pattern since the pattern is not directly formed on a cured green sheet, but formed in a flexible state using a peel sheet having a pattern formed therein by means of a tape casting method, the pattern can be formed more easily.
  • the problems regarding formation of air bubbles caused upon attachment to a final product can be prevented.
  • FIG. l a shows a ferrite sheet according to the prior art in which grooves are formed using a blade (left) or a hole drill (right).
  • FIG. lb shows a ferrite sheet according to one exemplary embodiment of the present invention in which grooves are formed on a ferrite green sheet using a patterned peel liner having grooves already formed therein.
  • FIG. 2 shows a scanning electron microscope (SEM) image of a ferrite green sheet according to the prior art.
  • FIG. 3a shows another SEM image of a ferrite green sheet according to the prior art, and
  • FIG. 3b shows the SEM image of a ferrite green sheet according to one exemplary embodiment of the present invention.
  • FIG. 4 shows a patterned peel liner configured to provide grooves in a ferrite green sheet.
  • FIG. 5 shows a ferrite green sheet having a pattern formed therein according to one exemplary embodiment of the present invention.
  • FIG. 6 shows a sintered ferrite sheet having a pattern formed therein according to one exemplary embodiment of the present invention.
  • FIG. 7 shows a ferrite green sheet having a lattice-type pattern according to one exemplary embodiment of the present invention.
  • FIGS. 8 and 9 show ferrite composite sheets including a hard-coated protective layer, a patterned ferrite sheet, and an acrylic pressure-sensitive adhesive (PSA) together with a peel liner according to one exemplary embodiment of the present invention.
  • PSA acrylic pressure-sensitive adhesive
  • FIG. 10 shows a ferrite composite sheet including an embossed pressure-sensitive adhesive tape according to one exemplary embodiment of the present invention.
  • FIG. 1 1 a shows that air bubbles are generated when using a sheet including an unembossed pressure-sensitive adhesive tape.
  • FIG. 1 lb shows that air bubbles are not generated in a final product when using a ferrite composite sheet including an embossed pressure-sensitive adhesive tape according to one exemplary embodiment of the present invention.
  • FIG. 12 shows the permeability characteristics of a ferrite sheet having grooves formed therein.
  • FIG. 13 shows an Agilent E4991A RF Impedance/Material Analyzer (FIG. 13a) and a
  • One exemplary embodiment of the present invention provides a ferrite green sheet having a pattern formed on a top surface thereof wherein the pattern includes a plurality of grooves, and each of the grooves has a round-shaped bottom, which has a radius of curvature R, and a width W.
  • a ratio (W:R) of W to R is in a range of 1 :0.1 to 1 :0.5.
  • the pattern is preferably a lattice-type pattern.
  • the pattern may be formed by coating a ferrite slurry on a patterned peel liner and drying the ferrite slurry.
  • the ferrite slurry preferably includes a ferrite powder, a solvent, a dispersing agent, a binder, and a plasticizer.
  • the ferrite powder is preferably a powder of soft spinel ferrite.
  • the ferrite powder is more preferably a powder of Ni-Zn-Cu-based spinel ferrite or Mg-Zn-Cu-based spinel ferrite.
  • the powder of Ni-Zn-Cu-based spinel ferrite preferably has a composition including Fe 2 0 3 at 40 to 50 mole%, NiO at 10 to 30 mole%, ZnO at 10 to 30 mole%, and CuO at 0 to 20 mole%, based on the total amount of the composition.
  • the powder of Mg- Zn-Cu-based spinel ferrite preferably has a composition including Fe 2 0 3 at 40 to 50 mole%, MgO at 15 to 35 mole%, ZnO at 5 to 25 mole%, and CuO at 0 to 20 mole%, based on the total amount of the composition.
  • a crystallized ferrite powder may be obtained by uniformly mixing a powdery oxide source, followed by calcining the oxide source at 750 ° C to 950 ° C for 2 hours and milling the calcined oxide source. It is desirable to use a ferrite powder having a cumulative 50% volume particle size of 0.5 to 1 .5 ⁇ .
  • the solvent that may be used herein may include a glycol ether-based solvent, MEK, toluene, methanol, ethanol, n-butanol, and the like.
  • a dispersing agent such as a copolymer, known in the related art may be used as the dispersing agent.
  • the binder that may be used herein preferably includes a thermoplastic resin such as polyethylene, polypropylene, or polyvinyl butyral, and a thermoplastic elastomer such as a styrene-, ethylene-, butylene- or olefin-based elastomer, which may be used alone or in combination.
  • a thermoplastic resin such as polyethylene, polypropylene, or polyvinyl butyral
  • a thermoplastic elastomer such as a styrene-, ethylene-, butylene- or olefin-based elastomer, which may be used alone or in combination.
  • polyvinyl butyral and polybutylmethacrylate may be used.
  • the plasticizer that may be used herein preferably includes bis(2- ethylhexyl)phthalate and butyl butyl phthalate.
  • the ferrite substrate according to the present invention has a pattern formed at a top surface thereof.
  • the pattern includes a plurality of grooves.
  • Each of the grooves installed at the top surface of the ferrite substrate has a round-shaped bottom.
  • R represents a radius of curvature of the round-shaped bottom
  • W represents a width of each of the grooves
  • each of the grooves has a ratio (W:R) of W to R ranging from 1 :0. 1 to 1 :0.5.
  • the ratio (W:R) of W to R is greater than or equal to 1 :0. 1
  • the grooves are formed in a round shape, which is distinguished from a V shape of each conventional groove in which burrs or particles are formed.
  • Gaps between the grooves may be in a range of 2 mm to 4 mm.
  • the ferrite substrate exhibits excellent permeability and processability, whereas the ferrite substrate exhibits excellent flexibility when the gaps between the grooves are less than or equal to 4 mm.
  • a green sheet having grooves formed therein is manufactured by subjecting a patterned peel liner to liquid coating. In this case, a more precise and elaborate pattern may be formed according to the present invention using a more simple process.
  • FIG. 2 shows the SEM image of a ferrite green sheet according to the prior art. As shown in FIG. 2, V-shaped grooves are formed on a ferrite sheet, and a plurality of particles are present in each of the grooves.
  • the ferrite green sheet according to the prior art has V-shaped grooves formed at a top surface thereof, as shown in FIG. 3a.
  • the ferrite green sheet according to the present invention has round-shaped grooves, as shown in FIG. 3b.
  • a patterned peel liner configured to provide grooves in a ferrite green sheet is shown in FIG. 4.
  • FIG. 4 since grooves arranged in a lattice-type mode are present in the peel liner, liquid coating may be performed using the peel liner in order to manufacture a green sheet having round-shaped grooves, as shown in FIGS, lb and 3b.
  • the pattern of the peel liner shown in FIGS, l b and 3b may be spontaneously printed onto the green sheet (see FIGS. 5 and 6).
  • This method does not require a separate process (i.e., a mechanical process) to form a pattern on the ferrite green sheet.
  • a separate process i.e., a mechanical process
  • a separate mechanical process for forming a pattern is required.
  • the entire process speed may be slow, and a bottleneck state may be caused throughout the processes of
  • a ferrite sheet is manufactured according to the present invention.
  • productivity may be enhanced and a more precise surface of the ferrite sheet may be formed upon manufacture of the ferrite sheet, which results in a decrease in overall manufacturing costs.
  • a half cut process is not required, and the breakaway of particles basically does not take place. That is, the present invention does not require a separate mechanical process since a slurry in a liquid state is cast, that is, coated on a peel liner having a pattern formed therein, and a pattern is spontaneously formed at the same time. Also, since the process is carried out when the slurry is in a flexible state before a sintering process, it is easy to handle, and it is possible to optionally control formation of the pattern.
  • the pattern formed on the ferrite green sheet of the present invention is preferably a lattice-type pattern.
  • Arranging a plurality of grooves in a lattice- type mode is realized to perform a breaking task for making ferrite flexible.
  • a breaking task for making ferrite flexible.
  • Another exemplary embodiment of the present invention provides a ferrite green sheet having a pattern formed at a top surface thereof wherein the pattern includes a concave portion extending therefrom, and the concave portion has a round-shaped bottom having a radius of curvature R and a top surface having a width W.
  • a ratio (W:R) of W to R is in a range of 1 :0. 1 to 1 :0.5.
  • the above-described ferrite green sheet according to one exemplary embodiment of the present invention is as described above.
  • Still another exemplary embodiment of the present invention provides a sintered ferrite sheet having a pattern formed at a top surface thereof wherein the pattern includes a plurality of grooves, and each of the grooves has a round-shaped bottom, which has a radius of curvature R, and a width W.
  • a ratio (W:R) of W to R is in a range of 1 :0.1 to 1 :0.5.
  • the pattern is preferably a lattice-type pattern, and the pattern may be formed by coating a ferrite slurry, which includes a ferrite powder, a solvent, a dispersing agent, a binder, and a plasticizer, on a patterned peel liner and drying the ferrite slurry.
  • the ferrite powder is as already described above.
  • the sintered ferrite sheet preferably has a a magnetic permeability with a real part ur' of 80 or more and an imaginary part ur" of 20 or less at 13.56 MHz. Also, the sintered ferrite sheet preferably has a real permeability ur' of 80 or more and an imaginary permeability ur" of 100 or less at 13.56 MHz.
  • the real permeability ur' and the imaginary permeability ur" at 13.56 MHz may be maintained at constant values of 80 or more and 20 or less, respectively. This is because the sintered ferrite is endowed with suitable flexibility.
  • the sintered ferrite also has very excellent properties as a thin-film sintered ferrite substrate for a loop antenna module, which has a thickness of 25 to 360 ⁇ .
  • the real permeability ur' and the imaginary permeability ur" at 13.56 MHz may be maintained at constant values of 80 or more and 100 or less, respectively. This is because the sintered ferrite is endowed with suitable flexibility.
  • the sintered ferrite also has very excellent properties as a thin-film sintered ferrite substrate for a loop antenna module, which has a thickness of 25 to 360 ⁇ .
  • the real permeability represents how well a magnetic field travels
  • the imaginary permeability represents a degree of loss of the magnetic field.
  • An ideal material is a material exhibiting high permeability and having low permeability loss.
  • the ferrite sheet having the above-described permeability may be used as a magnetic member suitable for use for antenna modules, which contributes to manufacturing a thin- film antenna module.
  • a sintered ferrite sheet may be manufactured by forming a ferrite green sheet having a pattern formed thereon, and sintering the ferrite green sheet in a calcining furnace. This is substantially similar to a process of cutting a clay dough to form grooves and curing the clay dough in a firing oven.
  • the calcination is performed after 5 to 20 ferrite green sheets are stacked on an alumina plate.
  • removal of resin components using an electric furnace and growth of ferrite particles should be taken into account. The removal of the resin components may be performed at 150 C to 550 ° C for 5 to 80 hours, and the growth of the ferrite particles may be performed at 850 ° C to 1 ,200 ° C for 1 to 5 hours.
  • the removal of the resin components may be performed at room temperature to a predetermined temperature after the ferrite sheet is heated at a heating rate of I O C to 20 ° C per hour. Thereafter, the ferrite sheet may be heated at a heating rate of 30 ° C to 60 ° C per hour, and sufficiently sintered at a constant temperature to grow ferrite particles, which are then cooled slowly.
  • the maintenance temperature or time required for each process may be optimally set according to the number of ferrite sheets to be processed.
  • Still another exemplary embodiment of the present invention provides a ferrite composite sheet including the sintered ferrite sheet.
  • the ferrite composite sheet may further include one or both of a pressure-sensitive adhesive layer and a conductive layer formed at one or both surfaces of the sintered ferrite sheet.
  • the ferrite composite sheet may be preferably configured to include a pressure-sensitive adhesive layer, a conductive layer stacked on the pressure-sensitive adhesive layer, a sintered ferrite sheet stacked on the conductive layer, a pressure-sensitive adhesive layer stacked on the sintered ferrite sheet, and a protective film stacked on the pressure-sensitive adhesive layer.
  • a pressure- sensitive adhesive may be used as the pressure-sensitive adhesive layer.
  • a breaking work is carried out to make a ceramic such as ferrite flexible.
  • a pressure-sensitive adhesive tape may be stacked on/under a sintered ferrite sheet so as to prevent scattering of the ceramic (i.e., the sintered ferrite sheet). Since the sintered ferrite sheet itself may be easily broken, a tape may be attached to the sintered ferrite sheet to improve workability and flexibility.
  • the pressure-sensitive adhesive tape may preferably include an air-containing portion.
  • an embossed tape may be used as the pressure-sensitive adhesive tape including such an air-containing portion.
  • the embossed tape serves to accommodate air bubbles or foam that may be generated between the sintered ferrite and the substrate (an antenna or a battery). Therefore, the problems regarding the air bubbles that may be caused in the final products may be solved.
  • the embossed tape may be attached to one or both surfaces of the sintered ferrite sheet. It is more desirable to attach the embossed tape to both surfaces of the sintered ferrite sheet. This is because air bubbles may always be generated between layers.
  • an embossed single-coated film (EMBO SCT) or an embossed dual-coated film (EMBO DCT) may be used as the embossed tape.
  • the embossed single-coated film may be attached to a top surface of the sintered ferrite sheet (a surface in which the protective film is attached onto the pressure-sensitive adhesive layer), and the embossed dual-coated film may be attached to a bottom surface of the sintered ferrite sheet (a surface in which the peel liner is attached to the pressure-sensitive adhesive layer) (see FIG. 10).
  • Yet another exemplary embodiment of the present invention provides a conductive loop antenna module including a magnetic member including the sintered ferrite sheet, a conductive loop antenna installed at one surface of the magnetic member, and a conductive layer installed opposite to the surface of the magnetic member having the conductive loop antenna formed therein.
  • the conductive loop antenna module may be used in wireless communication media and wireless communication medium processing apparatuses.
  • the magnetic member may be a Ni-Zn-Cu-based spinel ferrite-sintered substrate, or a Mg-Zn-Cu-based spinel ferrite-sintered substrate.
  • the conductive loop antenna may be manufactured by forming a conductive loop having a thickness of 20 to 30 ⁇ on one surface of an insulation film having a thickness of 20 to 60 ⁇ such as a polyimide film or a PET film.
  • the conductive loop may be in a spiral shape.
  • the conductive layer may be formed by applying an acrylic or epoxy-based conductive paint, or formed by printing and laminating a silver paste onto a ferrite molded sheet and integrally calcining the ferrite molded sheet.
  • the conductive layer may preferably have a thickness of 50 ⁇ or less and a surface electric resistivity of 3 ⁇ /D or less.
  • a paint obtained by dispersing a powder of copper and silver, which serves as a conductive filler, in an organic solvent such as butyl acetate or toluene, an acrylic resin, or an epoxy resin may be used as the conductive paint.
  • the sintered ferrite substrate to which a conductive layer is attached may be obtained by forming a conductive paste according to a green sheet method and integrally calcining the conductive paste.
  • an insulating protective film may be stacked on the conductive layer. Condensers are inserted into a loop in parallel, and a resonance frequency is adjusted to 13.56 MHz so as to allow the manufactured antenna module to resonate at desired frequencies.
  • the antenna module in which the conductive loop antenna, the pressure-sensitive adhesive layer, the ferrite sintered substrate, and the conductive layer are closely adhered and integrated and the condensers are introduced into a loop circuit in parallel so as to adjust the resonance frequency to 13.56 MHz, is installed in the vicinity of metal members of various types of electronic equipment, a stable
  • the antenna module may be used in a non-contact IC tag using the RFID/NFC technology.
  • the ferrite green sheet is manufactured using a method including the following operations:
  • preparing a ferrite powder forming a ferrite slurry by mixing the ferrite powder with a binder, a plasticizer, a solvent, and a dispersing agent;
  • a ferrite green sheet having grooves formed therein by coating the ferrite slurry on a patterned peel liner using a tape casting method, and drying the ferrite slurry.
  • a ball mill may be used.
  • the solvent and the ferrite powder are first filled and mixed and the binder and the plasticizer are then added, the ferrite slurry may be uniformly obtained.
  • the resulting slurry may be sufficiently degassed under a reduced pressure in a vacuum container so as to prevent cracks from occurring during the coating and drying processes.
  • a tape casting method is used upon coating of the ferrite slurry.
  • ceramic products especially electronic ceramic products, there are many very thin plate-shaped products.
  • each of the very thin plate-shaped products may include a substrate, a multilayer chip capacitor (MLCC), a multilayer inductor, a thermistor, a fuel cell, and the like.
  • MLCC multilayer chip capacitor
  • thermistor thermistor
  • fuel cell fuel cell, and the like.
  • methods used as plate-shaped ceramic molding methods a method which has been most widely used is the tape casting method.
  • This method is a method of obtaining a tape-type molded product by mixing a fine ceramic powder with a liquid-phase solvent such as alcohol or water to form a slurry, thinly plating the slurry on an underlying tape (i.e., a stainless steel tape, an oilpaper tape, or a polymer tape such as MYLAR or ACLAR) using a tape caster, volatilizing the solvent, and removing a film of the slurry from the underlying tape.
  • a liquid-phase solvent such as alcohol or water
  • the ferrite composite sheet is manufactured using a method including the following operations: preparing a ferrite powder;
  • a ferrite slurry by mixing the ferrite powder with a binder, a plasticizer, a solvent, and a dispersing agent;
  • a ferrite green sheet having grooves formed therein by coating the ferrite slurry on a patterned peel liner using a tape casting method, and drying the ferrite slurry; peeling the patterned peel liner from the ferrite green sheet and sintering the ferrite green sheet; and
  • a ferrite composite sheet by stacking a pressure-sensitive adhesive on both surfaces of the sintered ferrite sheet, stacking a protective film on one surface of the pressure-sensitive adhesive and stacking a peel liner on the other surface of the pressure- sensitive adhesive.
  • a Ni-Zn ferrite powder having the following composition was prepared.
  • Plasticizer bis(2-ethylhexyl) phthalate (CAS No. 1 17-81 -7)
  • Primary mixing was performed by optimally suspending a ferrite powder to form a slurry. When the primary mixing was completed, secondary mixing was performed.
  • the mixing conditions used in the primary and secondary mixings are listed in the following
  • grooves were mainly mechanically formed with a blade or a drum having grooves formed therein prior to a sintering process.
  • groove formation and tape casting may be performed at the same time. This is because a patterned peel liner is used.
  • the tape casting method of the present invention may aid in increasing the yield of the final product and improving the productivity, compared to the conventional method of mechanically forming grooves.
  • FIG. l a shows a ferrite green sheet whose grooves are formed using a blade
  • the right panel of FIG. l a shows a ferrite green sheet whose grooves are formed using hole drilling
  • FIG. lb shows a ferrite green sheet whose pattern is formed using a patterned peel liner according to the present invention.
  • the pattern of grooves formed on the ferrite green sheet as shown in FIG. lb is shown in FIG. 5.
  • the ferrite slurry was coated on a silicone- coated patterned liner using a tape caster, and dried to manufacture a ferrite green sheet having a thickness of 50 to 200 ⁇ .
  • a slurry coating rate was in a range of 2 to 5 m/minute, a temperature of a drying furnace was in a range of 60 ° C to 80 ° C , and a drying time was 5 minutes.
  • the drying conditions were associated with the boiling points of organic solvent components used in the ferrite slurry. From the tape casting results, it was confirmed that the ferrite green sheet had a green density of 3.5 g/cm 3 to 3.8 g/cm 3 .
  • FIG. 4 shows a patterned peel liner configured to form grooves on the ferrite green sheet.
  • SRF characteristics and qualities of the ferrite sheet at 13.56 MHz may be improved by controlling the magnetic permeability of a ferrite plate.
  • the shape of grooves affects excellent mechanical properties so that stress caused by a driving power can be lowered during a sintering process.
  • flexibility may be improved, and formation of air bubbles may be inhibited.
  • a sheet laminating process is additionally performed.
  • a desired thickness of the ferrite green sheet should be determined in consideration of the shrinkage rate of the ferrite green sheet.
  • the shrinkage rate of the ferrite green sheet is in a range of 25% to 15% in the Z axis, and in a range of 5% to 15% in the XY axes.
  • the iso-pressing process may be omitted according to a situation.
  • the ferrite green sheet is detached from the silicone-coated patterned peel liner.
  • the ferrite green sheet is sintered in a calcining furnace to perform combustion of a binder and densification of ferrite particles.
  • the sintered ferrite sheet having grooves formed therein is shown in FIG. 6.
  • a protective tape is attached to top and bottom surfaces of the sintered ferrite sheet.
  • the protective tape may be attached to the sintered ferrite sheet to improve workability and flexibility.
  • a pressure-sensitive adhesive used in the protective tape includes an air layer configured to exhaust air between the sintered ferrite sheet and the substrate.
  • air bubbles may be formed in the final product.
  • an embossed protective tape including such an air layer the air bubbles in the final product may be removed according to the present invention. Referring to FIGs. 1 1 a and 1 lb, it could be seen that the use of the embossed protective tape (FIG. 1 lb) prevented formation of air bubbles, but the use of an unembossed protective tape (FIG. 1 l a) resulted in formation of air bubbles.
  • a product was manufactured in a sandwich structure so that the product included a hard-coated protective layer, a patterned ferrite sheet, and an acrylic pressure- sensitive adhesive (PSA) together with a peel liner. This is because formation of air bubbles may be avoided during a stacking process.
  • the structures of the ferrite composite sheets are shown in FIGS. 8 and 9.
  • FIG. 12 shows the permeability characteristics of a ferrite sheet having patterns formed therein.
  • the permeability characteristics of the soft magnetic material can be measured, and the permeability can be analyzed using an RF impedance/material analyzer (commercially available from Agilent Technologies, Inc. ; see FIG. 13a) and a 16454A fixture (see FIG.

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  • Ceramic Engineering (AREA)
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  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
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Abstract

La présente invention concerne une feuille crue en ferrite, qui comprend un motif formé dans une surface supérieure de la feuille crue en ferrite, une feuille en ferrite frittée, une feuille composite en ferrite qui les comprend, et un module à antenne cadre conductrice. Le motif comprend une pluralité de rainures, chaque rainure possédant une largeur W et un fond de forme arrondie qui possède un rayon de courbure de R, un rapport de W à R (W:R) étant dans la plage allant de 1:0,1 à 1:0,5.
PCT/US2013/072634 2012-12-06 2013-12-02 Feuille crue en ferrite, feuille en ferrite frittée, feuille composite en ferrite les comprenant, et module à antenne cadre conductrice WO2014088954A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
CN201380063914.6A CN104885166B (zh) 2012-12-06 2013-12-02 铁氧体生片材、烧结铁氧体片材、包括烧结铁氧体片材的铁氧体复合材料片材以及导电环形天线模块
US14/649,568 US9847577B2 (en) 2012-12-06 2013-12-02 Ferrite green sheet, sintered ferrite sheet, ferrite composite sheet comprising the same, and conductive loop antenna module
JP2015546536A JP6509123B2 (ja) 2012-12-06 2013-12-02 フェライトグリーンシート、焼結フェライトシート、これを含むフェライト複合シート、及び導電性ループアンテナモジュール

Applications Claiming Priority (4)

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KR20120141485 2012-12-06
KR10-2012-0141485 2012-12-06
KR1020130083828A KR101476044B1 (ko) 2012-12-06 2013-07-16 페라이트 그린 시트, 소결 페라이트 시트, 이를 포함하는 페라이트 복합시트 및 도전 루프 안테나 모듈
KR10-2013-0083828 2013-07-16

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WO2017010447A1 (fr) * 2015-07-14 2017-01-19 戸田工業株式会社 Stratifié de ferrite et feuille de suppression de bruit
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WO2017010447A1 (fr) * 2015-07-14 2017-01-19 戸田工業株式会社 Stratifié de ferrite et feuille de suppression de bruit
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US10587049B2 (en) 2015-12-08 2020-03-10 3M Innovative Properties Company Magnetic isolator, method of making the same, and device containing the same
US10734725B2 (en) 2015-12-08 2020-08-04 3M Innovative Properties Company Magnetic isolator, method of making the same, and device containing the same
EP3493325A1 (fr) * 2017-11-29 2019-06-05 Premo, S.A. Antenne basse fréquence triaxiale à profil ultra-faible destinée à être intégrée dans un téléphone mobile et téléphone mobile la comprenant
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CN113936893A (zh) * 2021-10-11 2022-01-14 天通凯立科技有限公司 一种多层复合软磁铁氧体磁心制造方法

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