Patent Application
20230022220
The present application is based on, and claims priority from JP Application Serial Number 2021-117938, filed Jul. 16, 2021, the disclosure of which is hereby incorporated by reference herein in its entirety.
The present disclosure relates to a soft magnetic alloy ribbon and a magnetic core.
JP-A-2012-199506 discloses a soft magnetic alloy ribbon which is manufactured by a rapid solidification method and which includes, on a surface, a concave portion formed by irradiation with a laser beam and a protruding portion formed around the concave portion. JP-A-2012-199506 further discloses a tape-wound magnetic core formed by winding the soft magnetic alloy ribbon such that the concave portion is on the outside.
When the soft magnetic alloy ribbon is subjected to a heat treatment while applying a magnetic field in a longitudinal direction, magnetic domains generated along the longitudinal direction are formed antiparallel with a 180° domain wall sandwiched between the magnetic domains.
Here, when the soft magnetic alloy ribbon is irradiated with the laser beam in advance, finer magnetic domains are formed as compared with a case without irradiation with the laser beam. That is, due to the irradiation with the laser beam, refinement of the magnetic domains with the heat treatment becomes remarkable. By the refinement of the magnetic domains in this way, it is possible to reduce an eddy current loss and obtain a magnetic core with a low iron loss.
JP-A-2012-199506 further discloses that the iron loss can be particularly reduced by optimizing a height of the protruding portion and a ratio of a depth of the concave portion to a thickness of the ribbon.
JP-A-2012-199506 discloses an optimum condition for the irradiation with the laser beam, that is, the depth of the concave portion and the height of the protruding portion formed by a laser scribe treatment. However, the refinement of the magnetic domains is greatly influenced by an alloy composition of the ribbon and mechanical properties of the ribbon associated with the alloy composition. Consequently, it may not be possible to sufficiently refine the magnetic domains only by optimizing the conditions in the laser scribe treatment. Thus, it is required to refine the magnetic domains regardless of the alloy composition of the ribbon.
A soft magnetic alloy ribbon according to an application example of the present disclosure is a ribbon made of a Fe-based soft magnetic alloy and includes a first laser peening trace row and a second laser peening trace row each of which includes a plurality of laser peening traces in a row in a first direction and which are arranged adjacent to each other in a second direction intersecting the first direction, in which σ0<σ1, where a straight line at an equal separation distance from the first laser peening trace row and the second laser peening trace row is defined as a central line, a circle which is located around a center of the laser peening traces constituting the first laser peening trace row and which has a first radius shorter than the separation distance is defined as a first reference circle, a straight line which passes through the center and is parallel to the second direction is defined as a reference line, an in-plane stress at an intersection of the reference line and the central line is defined as σ0, and an in-plane stress on a circumference of the first reference circle is defined as σ1.
A magnetic core according to an application example of the present disclosure includes the soft magnetic alloy ribbon according to the application example of the present disclosure.
Hereinafter, a soft magnetic alloy ribbon and a magnetic core according to the present disclosure will be described in detail based on preferred embodiments shown in the drawings.
The soft magnetic alloy ribbon according to the embodiment is a ribbon made of a soft magnetic alloy. The soft magnetic alloy is an alloy exhibiting soft magnetism. For example, a plurality of soft magnetic alloy ribbons are laminated to form a laminated body. Such a laminated body is used for a magnetic core of a transformer, for example.
In
The ribbon refers to one having a shape having a first surface 11 and a second surface 12 that have a front-to-back relation with each other, in which a distance between the first surface 11 and the second surface 12, that is, the thickness t of the soft magnetic alloy ribbon 1, is sufficiently shorter than the length L and the width W of the soft magnetic alloy ribbon 1.
The thickness t of the soft magnetic alloy ribbon 1 is not particularly limited, and is preferably 1 μm or more and 40 μm or less, and more preferably 5 μm or more and 30 μm or less. The soft magnetic alloy ribbon 1 having such a thickness t has both sufficient mechanical strength and reduction in eddy current loss. Accordingly, it is possible to implement a soft magnetic alloy ribbon 1 which can be wound with a small bending radius and from which a small magnetic core with a low iron loss can be prepared.
Since the width W of the soft magnetic alloy ribbon 1 is often determined by manufacturing devices and manufacturing methods of the soft magnetic alloy ribbon 1, the width W is not particularly limited and is preferably 5 mm or more, more preferably 10 mm or more and 500 mm or less, and still more preferably 20 mm or more and 300 mm or less.
Since the length L of the soft magnetic alloy ribbon 1 is determined at the time of manufacturing the soft magnetic alloy ribbon 1, the length L is not particularly limited as long as it is longer than the width W of the soft magnetic alloy ribbon 1. When the soft magnetic alloy ribbon 1 is used for winding up to manufacture a magnetic core, as an example, the length L of the soft magnetic alloy ribbon 1 is preferably 5 times or more, and more preferably 10 times or more the width W of the soft magnetic alloy ribbon 1.
Examples of the soft magnetic alloy include Fe-based soft magnetic alloys such as Fe—Si—B based, Fe—Si—B—C based, Fe—Si—B—Cr—C based, Fe—Si—Cr based, Fe—B based, Fe—B—C based, Fe—P—C based, Fe—Co—Si—B based, Fe—Si—B—Nb based, Fe—Si—B—Nb—Cu based, and Fe—Zr—B based alloys. The Fe-based soft magnetic alloy is excellent in soft magnetism and has a high saturation magnetic flux density, and is thus useful as a constituent material of the soft magnetic alloy ribbon 1 used for the magnetic core or the like.
The soft magnetic alloy may contain nanocrystals. The nanocrystals refer to crystal structures with a grain size of 1.0 nm or more and 30.0 nm or less. When such nanocrystals are contained, the soft magnetism of the soft magnetic alloy can be further improved. That is, it is possible to implement a soft magnetic alloy ribbon 1 that has both low coercive force and high magnetic permeability.
In the soft magnetic alloy ribbon 1, it is preferable that the above nanocrystals are contained in a total ratio of 50% by volume or more, and more preferably 70% by volume or more. Accordingly, a soft magnetic alloy ribbon 1 exhibiting particularly satisfactory soft magnetism can be obtained. In addition, the soft magnetic alloy ribbon 1 may contain a crystalline structure. The crystalline structure refers to a structure containing crystal grains having a grain size of more than 30.0 nm.
As the Fe-based soft magnetic alloy, among the above-mentioned series, the Fe—Si—B based alloy or the Fe—Si—B—C based alloy is particularly preferably used. The Fe—Si—B-based alloy is made of Fe, Si, B, and impurities. The Fe—Si—B-based alloy has a chemical composition in which, when the total content of Fe, Si, and B is 100 atomic %, a Fe content is 78 atomic % or more, a B content is 11 atomic % or more, and the total content of Si and B is 17 atomic % or more and 22 atomic % or less.
Fe is a metal element having a large magnetic moment and influences the magnetic flux density of the soft magnetic alloy ribbon 1. The Fe content is preferably 78 atomic % or more and 82 atomic % or less.
Si and B influence amorphous-forming ability of the Fe-based soft magnetic alloy. The Si content is preferably 2.0 atomic % or more and 6.0 atomic % or less, and more preferably 3.5 atomic % or more and 6.0 atomic % or less. The B content is preferably 12 atomic % or more and 16 atomic % or less, and more preferably 13 atomic % or more and 16 atomic % or less. As described above, the total content of Si and B is preferably 17 atomic % or more and 22 atomic % or less.
In the Fe-based soft magnetic alloy having such a chemical composition, in particular, by setting the Fe content within the above range, it is possible to improve the magnetic flux density while improving the amorphous-forming ability. Thus, it is possible to implement a soft magnetic alloy ribbon 1 which exhibits excellent soft magnetism derived from amorphous substances or nanocrystals formed from amorphous substances and has a high saturation magnetic flux density. In particular, by setting the total content of Si and B within the above range, it is also possible to implement a soft magnetic alloy ribbon 1 in which the iron loss is sufficiently reduced.
The soft magnetic alloy ribbon 1 according to the embodiment, as shown in
In the present specification, the direction in which the laser peening traces 15 form a row is referred to as a “first direction α”. In the present embodiment, as an example, the first direction α and the width direction X are parallel to each other. In the present specification, the term “parallel” means a state where an angle between two directions is 10° or less. However, the relation between the first direction α and the width direction X is not limited to this, and the first direction α may be non-parallel to the width direction X.
As shown in
As shown in
The laser peening trace 15 is a processing trace formed by irradiating the first surface 11 with a laser beam, and refers to a concave portion as shown in
As shown in
The domain walls 2 are located at boundaries between adjacent magnetic domains 3 in the second direction β. The magnetic domains 3 shown in
Hereinafter, the laser peening trace 15 and the domain wall 2 will be described in more detail.
A spacing between the laser peening trace rows 16 shown in
When the line spacing d1 is below the lower limit value, depending on conditions such as the composition of the soft magnetic alloy, an area in which the amorphous substances contained in the soft magnetic alloy ribbon 1 crystallize or the nanocrystals become enlarged increases, and the soft magnetism decreases, resulting in an increase in iron loss of the soft magnetic alloy ribbon 1. On the other hand, when the line spacing d1 exceeds the upper limit value, depending on other arrangement conditions of the laser peening traces 15 and the laser peening trace rows 16, the refinement of the magnetic domains 3 may be insufficient, and the iron loss of the soft magnetic alloy ribbon 1 may not be sufficiently reduced.
Adjacent laser peening trace rows 16 are preferably substantially parallel, but may be non-parallel. The laser peening trace rows 16 may also have parallel portions and non-parallel portions.
The first direction α shown in
The line spacing d1 is a distance between the centers of the laser peening traces 15 measured in a middle portion of the width W of the soft magnetic alloy ribbon 1. The middle portion refers to a region having a width half the width W centered on a midpoint of the width W. Thus, the laser peening trace row 16 may extend over the entire width W or only a part of the width W of the soft magnetic alloy ribbon 1 as long as at least a part of the laser peening trace row 16 is provided in the middle portion.
The spacing between the laser peening trace rows 16 may be constant in the entire soft magnetic alloy ribbon 1 or partially different in the soft magnetic alloy ribbon 1. That is, when the spacing between the laser peening trace rows 16 is measured at a plurality of locations in the middle portion of the width W of one soft magnetic alloy ribbon 1, the measured values may be the same as or different from each other. In the latter case, an average value of five measured values is the line spacing d1 of the soft magnetic alloy ribbon 1.
The laser peening traces 15 may be provided on only one of the first surface 11 and the second surface 12, or may be provided on both the surfaces. When the laser peening traces 15 are provided on both the surfaces, the range of the line spacing d1 may be satisfied in a state where the laser peening traces 15 provided on the second surface 12 are projected onto the first surface 11 and the projected laser peening traces 15 and the laser peening traces 15 provided on the first surface 11 match each other.
A spacing between the laser peening traces 15 in the laser peening trace row 16 shown in
When the spot spacing d2 is below the lower limit value, depending on conditions such as the composition of the soft magnetic alloy, the amorphous substances contained in the soft magnetic alloy ribbon 1 crystallize or the nanocrystals become enlarged, and the soft magnetism decreases, resulting in the increase in iron loss of the soft magnetic alloy ribbon 1. On the other hand, when the spot spacing d2 exceeds the upper limit value, depending on other arrangement conditions of the laser peening traces 15 and the laser peening trace rows 16, the refinement of the magnetic domains 3 may be insufficient, and the iron loss of the soft magnetic alloy ribbon 1 may not be sufficiently reduced.
The spot spacing d2 is a distance between the centers of adjacent laser peening traces 15 in one laser peening trace row 16 measured in the middle portion of the width W of the soft magnetic alloy ribbon 1. The center of the laser peening trace 15 is a center of a perfect circle inscribed in the laser peening trace 15.
The spacing between the laser peening traces 15 may be constant the entire soft magnetic alloy ribbon 1 or partially different in the soft magnetic alloy ribbon 1. That is, when the spacing between the laser peening traces 15 are measured at a plurality of locations in the middle portion of the width W of one soft magnetic alloy ribbon 1, the measured values may be the same as or different from each other. In the latter case, an average value of five measured values is the spot spacing d2 of the soft magnetic alloy ribbon 1.
When the laser peening traces 15 are provided on both the first surface 11 and the second surface 12, the range of the spot spacing d2 may be satisfied in a state where the laser peening traces 15 provided on the second surface 12 are projected onto the first surface 11 and the projected laser peening traces 15 and the laser peening traces 15 provided on the first surface 11 match each other.
A diameter of the laser peening trace 15 shown in
When the spot diameter d3 is below the lower limit value, depending on other arrangement conditions of the laser peening traces 15 and the laser peening trace rows 16, the refinement of the magnetic domains 3 may be insufficient, and the iron loss of the soft magnetic alloy ribbon 1 may not be sufficiently reduced. On the other hand, when the spot diameter d3 exceeds the upper limit value, the mechanical strength of the soft magnetic alloy ribbon 1 may decrease.
The spot diameter d3 is an average value of equivalent circle diameters of 10 or more laser peening traces 15 measured in the middle portion of the width W of the soft magnetic alloy ribbon 1. The equivalent circle diameter is the diameter of a perfect circle having the same area as the laser peening trace 15 when the first surface 11 is viewed in a plan view.
The equivalent circle diameters of the laser peening traces 15 may be the same as or different from each other.
A depth of the laser peening trace 15 shown in
When the spot depth d4 is below the lower limit value, depending on other arrangement conditions of the laser peening traces 15 and the laser peening trace rows 16, the refinement of the magnetic domains 3 may be insufficient, and the iron loss of the soft magnetic alloy ribbon 1 may not be sufficiently reduced. On the other hand, when the spot depth d4 exceeds the upper limit value, the mechanical strength of the soft magnetic alloy ribbon 1 may decrease.
The spot depth d4 is an average value of depths of 10 or more laser peening traces 15 measured in the middle portion of the width W of the soft magnetic alloy ribbon 1.
The depths of the laser peening traces 15 may be the same as or different from each other.
By using the line spacing d1 [mm] and the spot spacing d2 [mm] in the soft magnetic alloy ribbon 1, a number density D of the laser peening traces 15 can be calculated. Specifically, the number density D of the laser peening traces 15 is indicated by (1/d1)×(1/d2). The number density D is an index indicating the arrangement density based on the number of the laser peening traces 15. The number density D of the laser peening trace 15 is preferably 0.05 pieces/mm2 or more and 0.50 pieces/mm2 or less, more preferably 0.10 pieces/mm2 or more and 0.40 pieces/mm2 or less, and still more preferably 0.15 pieces/mm2 or more and 0.35 pieces/mm2 or less. When the number density D is within the above range, the refinement of the magnetic domains 3 by the laser peening traces 15 can be further optimized, and the iron loss of the soft magnetic alloy ribbon 1 can be further reduced.
When the number density D is lower than the lower limit value, the iron loss of the soft magnetic alloy ribbon 1 may not be sufficiently reduced. On the other hand, when the number density D exceeds the upper limit value, when the soft magnetic alloy ribbon 1 is curved with a small bending radius, the soft magnetic alloy ribbon 1 may be easily damaged such as broken.
The number density D is calculated based on a region having a length in the length direction Y of 30 cm or more in the middle portion of the width W of the soft magnetic alloy ribbon 1 where the laser peening trace rows 16 are arranged. When the length L of the soft magnetic alloy ribbon 1 is less than 30 cm, the number density D is calculated based on the total length.
When the laser peening traces 15 are provided on both the first surface 11 and the second surface 12, the range of the number density D may be satisfied in a state where the laser peening traces 15 provided on the second surface 12 are projected onto the first surface 11 and the projected laser peening traces 15 and the laser peening traces 15 provided on the first surface 11 match each other.
As described above, the soft magnetic alloy ribbon 1 has the domain walls 2. The relation between the position of the domain walls 2 and the position of the laser peening traces 15 is not particularly limited. In the present embodiment, as shown in
The domain wall 2 is a 180° domain wall. The 180° domain wall refers to a domain wall between adjacent magnetic domains when magnetization directions of the adjacent magnetic domains are opposite to each other. Thus, as shown in
A width of the domain wall 2, that is, the length of the domain wall 2 in the first direction α is not particularly limited, and is preferably 50 nm or less, more preferably 2 nm or more and 40 nm or less, and still more preferably 10 nm or more and 30 nm or less. This makes the domain walls 2 particularly easy to move due to an external magnetic field.
A width of the magnetic domain 3 after refinement, that is, a length of the magnetic domain 3 in the first direction α is not particularly limited, and is preferably 5 mm or less, more preferably 0.05 mm or more and 3 mm or less, and still more preferably 0.1 mm or more and 1 mm or less.
In the soft magnetic alloy ribbon 1, an in-plane stress σ0 at a middle position MP is different from an in-plane stress σ1 at a near position NP1 near the first laser peening trace row 161. Specifically, a relation of σ0<σ1 is established.
The middle position MP is a position where a central line CL, which has an equal separation distance α0 from the first laser peening trace row 161 and the second laser peening trace row 162, intersects a reference line DL. The central line CL is a straight line parallel to the first direction α. The reference line DL passes through the center of the laser peening trace 15 constituting the first laser peening trace row 161 and is a straight line parallel to the second direction β.
The near position NP1 is a position on the circumference of a first reference circle DC1 having a first radius r1 from the center of the laser peening trace 15 constituting the first laser peening trace row 161. The first radius r1 is a distance shorter than the above-mentioned separation distance α0, and is a distance defined by r1=d2/2. The d2 used in the definition of the first radius r1 is a spacing (spot spacing d2) between the laser peening traces 15 constituting the first laser peening trace row 161.
It is considered that such an in-plane stress distribution is caused by the laser scribe treatment. The in-plane stress is a scalar quantity called Von Mises stress. The cause of the in-plane stress distribution includes that, at the near position NP1, the soft magnetic alloy around the laser peening trace 15 is compressed by the formation of the laser peening trace 15, and a compressive stress is generated accordingly. The cause also includes that the compressive stress at the middle position MP is relatively small since the middle position MP is separated from the laser peening trace 15. By optimizing the in-plane stress distribution in this way, it is considered that the energy required for AC magnetization is reduced and the iron loss of the soft magnetic alloy ribbon 1 can be reduced.
As described above, the near position NP1 is not limited to one point because it is a position on the circumference of the first reference circle DC1. In
Thus, a relation of σ0<σ1a and a relation of σ0<σ1b are established. The in-plane stress σ1a and the in-plane stress σ1b may be equal to each other or different from each other.
In addition, in the soft magnetic alloy ribbon 1, the in-plane stress σ0 at the middle position MP is different from an in-plane stress σ2 at a near position NP2 near the second laser peening trace row 162. Specifically, a relation of σ0<σ2 is established.
The near position NP2 is a position where a second reference circle DC2 having a second radius r2 from the center of the laser peening trace 15 constituting the second laser peening trace row 162 intersects the reference line DL. The second radius r2 is a distance shorter than the above-mentioned separation distance α0, and is a distance defined by r2=d2/2. The d2 used in the definition of the second radius r2 is a spacing (spot spacing d2) between the laser peening traces 15 constituting the second laser peening trace row 162.
It is considered that such an in-plane stress distribution is also caused by the laser scribe treatment. That is, at the near position NP2, the soft magnetic alloy around the laser peening trace 15 is compressed by the formation of the laser peening trace 15, and the compressive stress is generated accordingly. On the other hand, as described above, since the middle position MP is separated from the laser peening trace 15, the compressive stress is relatively small at the middle position MP. By optimizing the in-plane stress distribution in this way, it is considered that the energy required for the magnetization is reduced and the iron loss of the soft magnetic alloy ribbon 1 can be reduced.
As described above, the near position NP2 is not limited to one point because it is a position on the circumference of the second reference circle DC2. In
Thus, a relation of σ0<σ2a and a relation of σ0<σ2b are established. The in-plane stress σ2a and the in-plane stress σ2b may be equal to each other or different from each other.
As described above, the soft magnetic alloy ribbon 1 according to the present embodiment is a ribbon made of a Fe-based soft magnetic alloy, and includes the first laser peening trace row 161 and the second laser peening trace row 162. The first laser peening trace row 161 and the second laser peening trace row 162 each include a plurality of laser peening traces 15 in a row in the first direction α, and are arranged next to each other in the second direction β intersecting the first direction α.
The straight line having the equal separation distance α0 from the first laser peening trace row 161 and the second laser peening trace row 162 is defined as the central line CL. Further, the circle which is located around the center of the laser peening trace 15 constituting the first laser peening trace row 161 and which has the first radius r1 shorter than the separation distance σ0 is defined as the first reference circle DC1. The straight line which passes through the center of the laser peening trace 15 and is parallel to the second direction β is defined as the reference line DL.
When the in-plane stress at the intersection (middle position MP) of the reference line DL and the central line CL is defined as σ0 and the in-plane stress on the circumference of the first reference circle DC1 is defined as σ1, the soft magnetic alloy ribbon 1 according to the present embodiment satisfies the relation of σ0<σ1.
By satisfying such a relation, the in-plane stress distribution is optimized in the soft magnetic alloy ribbon 1. That is, the in-plane stress distribution changes due to the laser scribe treatment, but when the in-plane stress distribution satisfies the relation of σ0<σ1, the domain walls 2 are easily moved due to an external magnetic field. Accordingly, the energy required for the AC magnetization is reduced, and the iron loss of the soft magnetic alloy ribbon 1 can be reduced.
Further, as described above, the circle which is located around the center of the laser peening trace 15 constituting the second laser peening trace row 162 and which has the second radius r2 shorter than the separation distance σ0 is defined as the second reference circle DC2. When the in-plane stress on the circumference of the second reference circle DC2 is defined as σ2, the soft magnetic alloy ribbon 1 according to the present embodiment satisfies the relation of σ0<σ2.
By satisfying such a relation, the in-plane stress distribution is further optimized in the soft magnetic alloy ribbon 1. That is, in the present embodiment, when the in-plane stress distribution satisfies the relation of σ0<σ2, the domain walls 2 are easily moved due to an external magnetic field. Accordingly, the energy required for the AC magnetization is further reduced, and the iron loss of the soft magnetic alloy ribbon 1 can be further reduced.
The soft magnetic alloy ribbon 1 does not necessarily have to satisfy the relation of σ0<σ2, but the relation of σ0<σ2 is preferably satisfied from the viewpoint of reducing the iron loss of the entire soft magnetic alloy ribbon 1.
The relation of σ0<σ1 and the relation of σ0<σ2 as described above do not have to be satisfied in the entire soft magnetic alloy ribbon 1, but may be satisfied in at least a part thereof. Specifically, it is preferably the relations are satisfied in a range of 30% or more, and more preferably satisfied in a range of 50% or more in terms of area ratio.
As described above, the direction in which the laser peening trace rows 16 are arranged is the second direction R, and the direction in which the domain wall 2 extends is the third direction γ. In the present embodiment, the second direction β and the third direction γ are parallel to each other.
Accordingly, for example, when the laser peening trace rows 16 are arranged along the length direction Y of the soft magnetic alloy ribbon 1, the domain wall 2 also extends along the length direction Y. Thus, since the axis of easy magnetization of the soft magnetic alloy ribbon 1 is the same as the length direction Y, when the magnetic core is prepared by winding the soft magnetic alloy ribbon 1, the axis of easy magnetization is the same as a circumferential direction of the magnetic core. As a result, for example, a soft magnetic alloy ribbon 1 suitable for a wound iron core or the like can be obtained.
The in-plane stresses σ0, σ1, and σ2 vary depending on the composition of the soft magnetic alloy. As an example, σ0 is preferably 50 MPa or more and 1000 MPa or less, more preferably 100 MPa or more and 800 MPa or less, and still more preferably 100 MPa or more and 700 MPa or less. This makes the domain walls 2 particularly easy to move due to an external magnetic field.
A ratio σ1/σ0 and a ratio σ2/ρ0 are each more than 1, preferably 2 or more, and more preferably 2 or more and 5 or less. Accordingly, the iron loss of the soft magnetic alloy ribbon 1 can be particularly reduced.
The in-plane stresses σ1 and σ2 may be the same as or different from each other.
The in-plane stresses σ0, σ1 and σ2 are measured by, for example, a method of emitting radioactive rays such as X-rays and analyzing the state of scattered X-rays, a method of using sound elasticity, a method of using a temperature distribution, and a method of using Raman scattered light.
The in-plane stresses σ0, σ1 and σ2 can also be obtained by numerical analysis using finite element analysis software. Examples of the finite element analysis software include ANSYS (registered trademark) and COMSOL (registered trademark). In the finite element analysis, by inputting initial conditions such as the composition of the soft magnetic alloy, the line spacing d1, the spot spacing d2, the spot diameter d3, and the spot depth d4, the Von Mises stress at each point in the soft magnetic alloy ribbon 1 can be calculated.
The spacing between the first laser peening trace row 161 and the second laser peening trace row 162, that is, the line spacing d1, is preferably 1 mm or more and 40 mm or less, as described above. When the line spacing d1 is within the above range, an arrangement density of the laser peening trace rows 16 in the soft magnetic alloy ribbon 1 can be optimized. As a result, the magnetic domains 3 can be satisfactorily refined, and the iron loss of the soft magnetic alloy ribbon 1 can be further reduced.
The spacing between the laser peening traces 15 in the laser peening trace row 16 including the first laser peening trace row 161 and the second laser peening trace row 162, that is, the spot spacing d2 is preferably 1.0 mm or less, as described above. When the spot spacing d2 is within the above range, the arrangement density of the laser peening traces 15 in the laser peening trace row 16 can be optimized. As a result, the magnetic domains 3 can be satisfactorily refined, and the iron loss of the soft magnetic alloy ribbon 1 can be further reduced.
In the soft magnetic alloy ribbon 1 according to the present embodiment, as described above, the iron loss is reduced.
Specifically, the iron loss of the soft magnetic alloy ribbon 1 under conditions of a frequency of 50 Hz and a magnetic flux density of 1.2 T is preferably 0.05 W/kg or less, more preferably 0.04 W/kg or less, and still more preferably 0.02 W/kg or less.
When the soft magnetic alloy ribbon 1 having such a low iron loss is used for a transformer or the like, the soft magnetic alloy ribbon 1 contributes to high efficiency of the transformer. For example, when the soft magnetic alloy ribbon 1 having such a low iron loss is used for a motor core or the like, the soft magnetic alloy ribbon 1 contributes to improvement of conversion efficiency. The iron loss is measured by, for example, sinusoidal excitation using an AC magnetic measuring instrument.
Next, soft magnetic alloy ribbons according to modifications will be described.
The soft magnetic alloy ribbon 1A shown in
As described above, since the domain walls 2 are provided regardless of the positions of the laser peening traces 15, as shown in
The soft magnetic alloy ribbon 1B shown in
As shown in
Even in the above-described modifications, the same effect as that of the above-described embodiment can be obtained.
Next, an example of a method for manufacturing the soft magnetic alloy ribbon will be described.
The method for manufacturing the soft magnetic alloy ribbon shown in
The material ribbon is manufactured by, for example, a method for manufacturing a rapidly solidified ribbon, such as a single roll method. The material preparation step S102 may be a step of manufacturing the material ribbon by such a manufacturing method, may include a step of cutting the material ribbon manufactured by the manufacturing method described above into a necessary length, or may be a step of only preparing the material ribbon.
In the laser processing step S104, the laser processing is performed on at least one main surface of the material ribbon to form the laser peening trace. The arrangement of the laser peening traces is the same as the arrangement of the laser peening traces 15 in the soft magnetic alloy ribbon 1 described above.
Conditions in the laser processing vary depending on the alloy composition and the like of the material ribbon. As an example, an output of laser in the laser processing is preferably 0.4 mJ or more and 2.5 mJ or less, and more preferably 1.0 mJ or more and 2.0 mJ or less.
A diameter of a laser beam in the laser processing influences the spot diameter d3 described above. As an example, the diameter of the laser beam is preferably 0.010 mm or more and 0.30 mm or less, and more preferably 0.020 mm or more and 0.25 mm or less.
An energy density of the laser in the laser processing influences the spot diameter d3 and the spot depth d4 of the laser peening trace 15 described above. As an example, the energy density of the laser is preferably 0.01 J/mm2 or more and 1.50 J/mm2 or less, and more preferably 0.03 J/mm2 or more and 1.00 J/mm2 or less.
A wavelength of the laser in the laser processing is, for example, preferably 250 nm or more and 1100 mm or less, and more preferably 900 nm or more and 1100 nm or less.
A laser light source used in the laser processing includes, for example, a YAG laser, a CO2 gas laser, a semiconductor laser, and a fiber laser. Among these, from the viewpoint of being capable of emitting high-frequency pulsed laser light with a high output, the fiber laser is preferably used. A pulse width of the pulsed laser light is preferably 50 nanoseconds or more, and more preferably 100 nanoseconds or more. The pulse width is a time during which laser irradiation is performed, and when the pulse width is smaller, the irradiation time is shorter. When the pulse width is set within the above range, the laser peening trace 15 having an appropriate size and depth can be efficiently formed.
The in-plane stresses σ0, σ1 and σ2 can be adjusted according to, for example, the energy density (power) of the laser, the pulse width of the pulsed laser light, a temperature and a cooling rate of the rapidly solidified ribbon, and the line spacing d1. Specifically, the compressive stress around the laser peening trace 15 can be increased by increasing the energy density of the laser or increasing the pulse width. Accordingly, the in-plane stresses σ1 and σ2 can be increased. The in-plane stresses σ0, σ1, and σ2 can also be increased when the temperature of the rapidly solidified ribbon is increased or the cooling rate is increased. On the other hand, by widening the line spacing d1, the in-plane stress σ0 can be lowered.
Next, a magnetic core according to the embodiment will be described.
A magnetic core 10 shown in
A shape of the magnetic core 10 is not limited to the shape shown in
It is preferable that the soft magnetic alloy ribbons 1 provided in the laminated body 17 are insulated from each other. For the insulation, for example, a resin coating can be used.
As described above, the magnetic core 10 includes the above-mentioned soft magnetic alloy ribbon 1. Accordingly, the magnetic core 10 with a low iron loss can be obtained. Such a magnetic core 10 is suitably used for, for example, a power distribution transformer, a high frequency transformer, a saturable reactor, a magnetic switch, a choke coil, a motor, and a generator.
The soft magnetic alloy ribbon and the magnetic core according to the present disclosure have been described above based on preferred embodiments, but the present disclosure is not limited thereto. For example, the soft magnetic alloy ribbon and the magnetic core according to the present disclosure may have any constituent added to the above embodiments.
Next, specific examples according to the present disclosure will be described.
First, a material ribbon made of a soft magnetic alloy having an alloy composition of Fe82Si4B14 and having a thickness of 25 μm and a width of 210 mm was manufactured by a single roll method. Fe82Si4B14 means an alloy composition in which when the total content of Fe, Si, and B is 100 atomic %, the Fe content is 82 atomic %, the Si content is 4 atomic %, and the B content is 14 atomic %.
Next, a sample piece having a size of a length of 120 mm and a width of 25 mm was cut out from the manufactured material ribbon.
Next, one main surface of the cut sample piece was subjected to a laser scribe treatment to form a laser peening trace. As shown in
Next, a heat treatment was performed at 340° C. for 1 hour while applying a magnetic field of 1.6 kA/m in the length direction of the soft magnetic alloy ribbon.
When the soft magnetic alloy ribbon after the heat treatment was observed by an electron holography using a transmission electron microscope, the magnetic domains and the domain walls as shown in
Next, the in-plane stresses σ0, σ1a, and σ2a were calculated by numerical analysis by using the finite element analysis software. The calculation results are shown in Table 1.
The soft magnetic alloy ribbon of each sample No. was obtained in the same manner as in the case of the soft magnetic alloy ribbon of sample No. 1, except that the processing conditions in the laser scribe treatment were changed to obtain the values of the in-plane stresses σ0, σ1a, and σ2a shown in Table 1.
The soft magnetic alloy ribbon of each sample No. was obtained in the same manner as in the case of the soft magnetic alloy ribbon of sample No. 1, except that the processing conditions in the laser scribe treatment were changed to obtain the values of the in-plane stresses σ0, σ1a, and σ2a shown in Table 2. The in-plane stresses σ1a and σ2a were made different from each other.
The soft magnetic alloy ribbon of each sample No. was obtained in the same manner as in the case of the soft magnetic alloy ribbon of sample No. 1, except that the processing conditions in the laser scribe treatment were changed to obtain the values of the in-plane stresses σ0, and σ1b shown in Table 3.
In Tables 1 to 3, the soft magnetic alloy ribbon corresponding to the present disclosure is referred to as “Example”, and a soft magnetic alloy ribbon not corresponding to the present disclosure is referred to as “Comparative Example”.
For the soft magnetic alloy ribbon of each Example and each Comparative Example, the iron loss was measured under the conditions of a frequency of 50 Hz and a magnetic flux density of 1.2 T. Then, measurement results were evaluated in light of the following evaluation criteria.
A: the iron loss is 0.02 W/kg or less
B: the iron loss is more than 0.02 W/kg and 0.05 W/kg or less
C: the iron loss is more than 0.05 W/kg
The evaluation results are shown in Tables 1 to 3.
As is clear from Tables 1 to 3, the soft magnetic alloy ribbons of Examples have an iron loss lower than that of the soft magnetic alloy ribbons of Comparative Examples. Thus, it has been found that, according to the present disclosure, a soft magnetic alloy ribbon from which a magnetic core having a low iron loss can be manufactured can be implemented.
Here, the in-plane stresses σ0 and σ1a shown in Table 1 were plotted in an orthogonal coordinate system to create a graph.
In
In addition, the in-plane stresses σ0 and σ1b shown in Table 3 were plotted in the orthogonal coordinate system to create a graph.
Also in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-117938 | Jul 2021 | JP | national |
