JPH0367617B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION A. Field of Industrial Application The present invention relates to an amorphous alloy laminated sheet and a method for producing the same, and for example, an amorphous alloy laminated sheet suitable for use as a magnetic core material, wallpaper, or other interior decoration material. This invention relates to an alloy laminated sheet and a method for manufacturing the same.

B. Prior art The magnetic cores used in transformers, chokes, noise filters (noise limiters) used in alternating current, and rotating electrical equipment such as motors and generators are made of silicon steel sheets, permalloy sheets, soft magnetic amorphous alloy thin sheets, etc. Laminated cores made of strips and powder cores made of iron powder, sendust powder, permalloy powder, etc. are used.

Amorphous alloys have attracted attention as various functional materials because they exhibit unique chemical and mechanical properties that are not found in ordinary crystalline alloys. Among them, amorphous alloys such as iron-based, cobalt-based, and nickel-based alloys do not exhibit crystal anisotropy, so they exhibit extremely good soft magnetic properties such as very small coercive force and high magnetic permeability. It is hoped that it will be put to practical use.

However, amorphous alloys are usually several tens of μm thick and wide.
It is supplied in a ribbon shape of about 100 mm, and it is extremely difficult to handle it because there are problems with damage when cutting it and adhesion when stacking it to make it into plates of the specified size. Moreover, in order to obtain a predetermined thickness, it is necessary to laminate many layers, which requires a large number of man-hours and is problematic in terms of productivity.

C. Purpose of the Invention The present invention has been made in view of the above circumstances, and is an amorphous alloy laminate sheet that retains the excellent properties of the amorphous alloy described above and has excellent productivity. The purpose of the present invention is to provide a method for producing the same.

D. Structure of the Invention The first invention of the present invention is made from amorphous alloy flakes having a thickness of 5 to 100 μm and an aspect ratio (however, the aspect ratio is the ratio of the maximum length to the minimum length) of 10 to 15,000. The present invention relates to an amorphous alloy laminate sheet comprising a layer consisting of the amorphous alloy flakes and a resin film, and the layer consisting of the amorphous alloy flakes and the resin film are integrated by heat-pressing.

A second aspect of the present invention is to uniformly arrange amorphous alloy flakes having a thickness of 5 to 100 μm and an aspect ratio of 10 to 15,000 on a resin film, and then to place the amorphous alloy flakes and the resin film together. The first aspect of the present invention relates to a method for producing an amorphous alloy laminated sheet according to the first invention, in which the amorphous alloy is heat-pressed and integrated at a temperature lower than the crystallization temperature of the amorphous alloy.

If the thickness of the amorphous alloy flakes is less than 5 μm, it will be difficult to manufacture the amorphous alloy flakes, and if it becomes thicker than 100 μm, it will be difficult to make it amorphous, so the thickness should be 5 to 100 μm. . A particularly preferred thickness is 20 to 60 μm.

If the aspect ratio of the amorphous alloy flakes is less than 10, lamination becomes difficult, and the magnetic permeability of the soft magnetic amorphous alloy flakes decreases. On the other hand, if the aspect ratio exceeds 15,000, handling of the amorphous alloy flakes becomes troublesome and productivity decreases. A particularly preferred range of aspect ratio is 50~
It is 10000.

The thermocompression bonding is performed at a temperature lower than the crystallization temperature of the amorphous alloy. When heated to a temperature higher than the crystallization temperature of the amorphous alloy, the amorphous alloy becomes crystalline and has the properties of a normal metal, losing the excellent properties unique to the amorphous alloy described above.

E. Examples First, preferred embodiments of the present invention will be described.

FIG. 1 is a plan view of an amorphous alloy laminate sheet according to the present invention, and FIG. 2 is an enlarged sectional view thereof.

An amorphous alloy laminate sheet 1 is constructed by laminating amorphous alloy flakes 2 between two plastic films 3 and joining them together by thermocompression bonding. However, in FIG. 1, the film 3 is not shown because it is thin and transparent.

As seen in FIG. 2, a part of the plastic film 3 melts due to heat and pressure bonding and enters the gap between the amorphous alloy flakes 2, and this intruded portion 3a
The upper and lower plastic films 3 are connected to each other, and the amorphous alloy composite sheet 1 is firmly integrated.

The amount of amorphous alloy flakes 2 per unit area is 2000 g/m ² because the larger the amount, the better the magnetic properties, but the loss of flexibility and the difficulty of handling.
If it is less than 5 g/m ² , the amount of plastic film will be relatively large and the amount of amorphous alloy flakes will be small, which will be disadvantageous in terms of magnetic properties. Therefore, the amount of amorphous alloy flakes is preferably 5 to 2000 g/ ^m2 , especially 50 to 2000 g/m2.
1000 g/m ² is a preferred amount.

If the thickness of the plastic film 3 is less than 5 .mu.m, it will be difficult to handle, and if it exceeds 500 .mu.m, the flexibility will be poor, so it is preferably 5 to 500 .mu.m.
A particularly preferred range is 20 to 100 μm.

To manufacture this amorphous alloy composite sheet, amorphous alloy flakes 2 weighed to a predetermined weight according to desired magnetic properties are placed on two plastic sheets 3.
It is only necessary to arrange the parts uniformly between the parts and heat and press them, and the manufacturing process is extremely easy. Moreover, since each amorphous alloy flake 2 is arranged and stacked uniformly with random directions, it is naturally non-directional. On the other hand, laminating amorphous alloy ribbons and crystalline alloy ribbons requires repeated cutting and gluing, and gluing in different cross directions and angles to make them non-directional. The work is extremely troublesome. In addition, if directionality is required in the present invention, by applying a slight magnetic field along a predetermined direction when uniformly arranging the amorphous alloy flakes, the amorphous alloy flakes can be aligned in the longitudinal direction and the orientation can be improved. can be granted.

Amorphous alloy flakes can be made by cutting from a ribbon or by a known melt extraction method, but from the viewpoint of productivity and the ability to make the peripheral edges of the amorphous alloy flakes thin, the present applicant proposed the cavitation method in JP-A No. 58-6907, in which molten metal is supplied to the surface of a roll that has a surface layer with low leakage to the molten metal and is rotating at high speed. It is desirable to apply a method in which the molten metal droplets are divided into fine molten metal droplets, and then the molten metal droplets are made to collide with a metal rotating body rotating at high speed to rapidly solidify.

Specific examples of the present invention will be described below.

Example 1 Amorphous metal flakes of C ₀₆₈ . ₈ Fe ₄ . ₂ Si ₁₆ B ₁₁ (the number attached to the element symbol represents the atomic percent of the elemental component; the same applies hereinafter) were produced by the cavitation method. did. The magnetostriction of this amorphous alloy is zero, the saturation magnetic flux density is 7000G, the magnetic permeability is 10000,
The crystallization temperature is 512°C. The average thickness of Mako's amorphous alloy flakes is 40μm, and the aspect ratio is 200.
~500.

This amorphous alloy flake is 600mm wide and 30μ thick.
250g per ^m2 on polyester film
30μ thick layer on top of it.
It was covered with a polyester film of m. This sandwich-like composite sheet is passed between two silicone rubber rolls heated to 100°C and crimped.
A long amorphous alloy laminate sheet having a thickness of 150 μm as shown in FIGS. 1 and 2 was prepared.

This sheet can be easily cut into desired shapes and dimensions with scissors, and can also be bent sharply at right angles.

An adhesive is applied in advance to a thickness of 1 μm on the side of the amorphous alloy flake layer of the above polyester film, and the amorphous alloy composite sheet is integrated by both adhesion and heat-pressing. The results obtained were similar to those in the above example.

Example 2 Amorphous alloy flakes having a composition of Fe ₇₂ C ₀₈ Si ₅ B ₁₅ were produced in the same manner as in Example 1. The magnetostriction of this amorphous alloy is +40×10 ^-6 and the saturation magnetic flux density is
16500G, crystallization temperature is 520℃. Moreover, the average thickness of this amorphous alloy flake is 30 μm, and the aspect ratio is 100 to 300.

The amorphous alloy flakes were placed and laminated uniformly on a 50 μm thick polyester film in an amount of 500 g ^per square meter, and a 15 μm thick polyester film was placed on top of the amorphous alloy flakes. Place the flakes evenly in an amount of 500g per ^1m2 .
They were laminated, and a 50 μm thick polyester film was further placed on top of the layers. This multi-layered sandwich-like composite sheet was heated to 200℃ using a press plate.
Heat and press at a pressure of 100Kg/cm ² for 30 minutes, 1m x 1
A regular-sized amorphous alloy laminate sheet with an average thickness of 250 μm was prepared.

As shown in an enlarged view in FIG. 3, this laminated sheet 11 includes a polyester film 13 ₁ , an amorphous alloy flake 12 , a polyester film 13 ₂ ,
The amorphous alloy 12 and the polyester film 13 ₁ are sequentially laminated, and the films 13 ₁ and 13 ₂ are connected and integrated by the film portion 13 a inserted into the space between the amorphous alloy flakes 12 by heat compression bonding. It's summery.

This sheet 11 can be easily cut into a desired shape and size with scissors, and can also be bent sharply at right angles.

The amorphous alloy laminate sheets of Examples 1 and 2 above are:
Any of these can be easily cut into a desired shape and size using scissors, cutters, etc., and therefore can be made into the laminated ring core 4 shown in FIG. 4, for example. Further, since it is easy to bend, it can be wound into a toroidal core 5 shown in FIG. 5, for example.

Example 3 Amorphous alloy flakes having a composition of Ni ₇₅ Si ₈ B ₁₇ were prepared in the same manner as in Example 1. The crystallization temperature of this amorphous alloy is 465°C. Moreover, the average thickness of this amorphous alloy flake is 50 μm, and the aspect ratio is 500 to 1000.

This amorphous alloy flake is 1m wide and 100μ thick.
Place and stack the film uniformly on a Teflon film of 1 m2 in an amount of 100 g per ^{1 m2} , and on top of that a 100 μm thick Teflon film.
covered with Teflon film. This sandwich-like composite sheet was passed between two metal rolls heated to 300°C and crimped to form a long amorphous alloy laminate with an average thickness of 250 μm as shown in Figures 1 and 2. It was made into a sheet.

This sheet can also be easily cut into desired shapes and dimensions with scissors, and can also be bent sharply at right angles.

Instead of heating the roll or press plate in Examples 1, 2, and 3, an adhesive is applied to one side of the plastic film to a thickness of about 1 μm, for example.
The amorphous alloy flake layer is sandwiched between the coated surfaces (in Example 2, adhesive is coated on both sides of the polyester film 13 ₂ ), and then cold bonded using a roll or press plate. It is also possible to integrate an amorphous alloy laminate sheet. In this method, a portion of the adhesive enters the gap between the amorphous alloy flakes, and the upper and lower films are connected via the adhesive (the structure is similar to that shown in Figures 2 and 3).
Therefore, the same effects as in the embodiment described above can be achieved. However, integration by heat and pressure bonding does not require the adhesive to be applied to the film in advance and does not require time for the adhesive to harden, which is advantageous in terms of productivity.

In addition, for the integration of amorphous alloy laminated sheets, 2
It is conceivable to use a vacuum packing technique in which amorphous alloy flakes are uniformly arranged between two plastic films and then the films are brought into close contact by reducing the pressure between the films. However, with this method, it is impossible to make the film completely follow and adhere to the uneven surface of the amorphous alloy flake layer, and the bending workability is not sufficiently satisfied. Furthermore, it goes without saying that if it is cut, the integrity cannot be maintained. Moreover, the film is easily torn due to external loads or rubbing, and breaks apart when the vacuum is released. On the other hand, in the case of an amorphous alloy laminated sheet integrated by heat-pressing, part of the film melts during heat-pressing and completely contacts the amorphous alloy flakes, causing the gaps between the amorphous alloy flakes to melt. Since it penetrates into the gaps and eliminates gaps within the sheet, bending is extremely easy and the mechanical strength is stable.

The material of the base (film) is not limited to the above-mentioned polyester film, polyethylene, and Teflon, and other thermoplastic resins such as polypropylene, polystyrene, and others can be used.

In addition, the amorphous alloy laminated sheet, which uses a resin film as the base material, has amorphous alloys with metallic luster arranged randomly, which forms a beautiful pattern and gives a sense of beauty. Due to the excellent corrosion resistance of the high-quality alloy, it retains its metallic luster for a long time, and it is easy to cut and has flexibility, so it is also suitable as an interior material for wall hangings, wallpaper, shoji paper, matte, etc. Can be used. Figure 6 shows the first
FIG. 3 is a schematic diagram of an interior room showing an example in which the amorphous alloy laminate sheet 1 of FIGS. 1 and 2 is used as wallpaper.

In addition, the two plastic films 3 in Figure 2
If a transparent plastic board is used in place of one or both of the parts, it can be similarly used as a wall board. In these cases, the amorphous alloy flakes do not need to have magnetism, and may be flakes of an alloy that can be made amorphous (for example, a non-magnetic cobalt-based, iron-based, nickel-based, or other alloy).

F. Effects of the Invention As explained above, the present invention has the following effects.

(1) Since the thickness of the amorphous alloy flakes is 5 to 100 μm, their amorphization is reliable, and the excellent magnetic properties or corrosion resistance characteristic of amorphous alloys can be obtained.

(2) Aspect ratio of amorphous alloy flakes is 10~
15,000, it is easy to handle and laminated.

(3) Since the amorphous alloy flakes and the substrate are integrated by heat and pressure bonding, the mechanical strength is stable and manufacturing is easy.

(4) Since the temperature of thermocompression bonding is lower than the crystallization temperature of the amorphous alloy, the excellent magnetic properties or corrosion resistance of the amorphous alloy are maintained.

(5) The amorphous alloy flakes and their excellent corrosion resistance provide a beautiful appearance with metallic luster.

[Brief explanation of drawings]

The drawings all show examples of the present invention, and FIG. 1 is a plan view of an amorphous alloy laminate sheet;
Fig. 2 is an enlarged sectional view of an amorphous alloy laminate sheet, Fig. 3 is an enlarged sectional view of another amorphous alloy laminate sheet,
4 and 5 are perspective views of the magnetic core, and FIG. 6 is a schematic diagram of a room showing an example in which an amorphous alloy laminated sheet is used as wallpaper. In addition, in the symbols shown in the drawings, 1, 11
...Amorphous alloy laminate sheet, 2,12...Amorphous alloy flakes, 3,13 ₁ ,13 ₂ ...Plastic film, 3a, 13a...Plastic film that has entered the gap between the amorphous alloy flakes Parts 4 and 5 are magnetic cores.

Claims (1)

[Claims] 1. A layer consisting of amorphous alloy flakes with a thickness of 5 to 100 μm and an aspect ratio (however, the aspect ratio is the ratio of the maximum length to the minimum length) of 10 to 15,000, and a resin film. An amorphous alloy laminate sheet comprising: a layer made of the amorphous alloy flakes and the resin film integrated by heat-pressing. 2 Amorphous alloy flakes with a thickness of 5 to 100 μm and an aspect ratio of 10 to 15,000 are uniformly arranged on a resin film, and then the amorphous alloy flakes and the resin film are combined with the crystals of the amorphous alloy. A method for manufacturing an amorphous alloy laminated sheet, which is integrated by heat-pressing at a temperature lower than the temperature at which the amorphous alloy laminates.