EP2483898B1 - Noyau de transformateur ou tôle de transformateur avec une structure amorphe et/ou nanocristalline et procédé pour sa fabrication - Google Patents

Noyau de transformateur ou tôle de transformateur avec une structure amorphe et/ou nanocristalline et procédé pour sa fabrication Download PDF

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Publication number
EP2483898B1
EP2483898B1 EP10749632.5A EP10749632A EP2483898B1 EP 2483898 B1 EP2483898 B1 EP 2483898B1 EP 10749632 A EP10749632 A EP 10749632A EP 2483898 B1 EP2483898 B1 EP 2483898B1
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EP
European Patent Office
Prior art keywords
layers
layer
soft magnetic
transformer
separating
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German (de)
English (en)
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EP2483898A1 (fr
Inventor
Gabriele Winkler
Thomas Hammer
Frank Heinrichsdorff
Jens Dahl Jensen
Volkmar LÜTHEN
Oliver Stier
Ursus KRÜGER
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Siemens AG
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Siemens AG
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
    • 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
    • H01F1/14—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 metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15333—Amorphous metallic alloys, e.g. glassy metals containing nanocrystallites, e.g. obtained by annealing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F10/00—Thin magnetic films, e.g. of one-domain structure
    • H01F10/08—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers
    • H01F10/10—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers characterised by the composition
    • H01F10/12—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers characterised by the composition being metals or alloys
    • H01F10/13—Amorphous metallic alloys, e.g. glassy metals
    • H01F10/131—Amorphous metallic alloys, e.g. glassy metals containing iron or nickel
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F10/00—Thin magnetic films, e.g. of one-domain structure
    • H01F10/08—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers
    • H01F10/10—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers characterised by the composition
    • H01F10/12—Thin magnetic films, e.g. of one-domain structure characterised by magnetic layers characterised by the composition being metals or alloys
    • H01F10/13—Amorphous metallic alloys, e.g. glassy metals
    • H01F10/132—Amorphous metallic alloys, e.g. glassy metals containing cobalt
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F10/00—Thin magnetic films, e.g. of one-domain structure
    • H01F10/26—Thin magnetic films, e.g. of one-domain structure characterised by the substrate or intermediate layers
    • H01F10/265—Magnetic multilayers non exchange-coupled
    • 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
    • H01F41/14—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 applying magnetic films to substrates
    • H01F41/24—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 applying magnetic films to substrates from liquids
    • H01F41/26—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 applying magnetic films to substrates from liquids using electric currents, e.g. electroplating

Definitions

  • the invention relates to a transformer core, comprising soft magnetic layers of an electrically conductive core material having an amorphous and / or nanocrystalline microstructure, which are separated from one another by separating layers of an electrically insulating material. Furthermore, the invention relates to a transformer sheet, comprising a soft magnetic layer of an electrically conductive core material having an amorphous and / or nanocrystalline microstructure, which is coated with a release layer of an electrically insulating material.
  • the invention also relates to a method for producing a transformer sheet or a transformer core.
  • a transformer core or transformer sheet of the type specified and a method for its production is, for example, in the DE 33 26 556 C2 described. Thereafter, a transformer sheet having an amorphous microstructure can be obtained, for example, by dropping the molten metal containing a glass-forming element onto a cooled substrate, thereby causing extremely rapid cooling of the dropped metal. As a result, the metal solidifies amorphous. Subsequently, the electrically insulating layer can be applied by electrochemical means by a cathodic electrodeposition. The resulting transformer sheets can be processed by laminating or winding into a transformer core in which the layer of the metal with the amorphous crystal structure alternate with the separation layers.
  • amorphous self-supporting films can be produced by electrochemical means, which have a thickness between 20 and 250 microns.
  • an alloy is deposited, which has iron as the main part, as a glass former phosphorus and another transition metal as alloying shares.
  • DE 33 46 659 A1 and the article " Solenoid-Type Thin-Film Micro-Transformer "by H. Kurata et al., IEEE Translation Journal on Magnetics, Japan, Vol. 9, No. 3, 1994 ) disclose transformers in which the magnetic core is formed of amorphous magnetic layers and insulating separation layers in monolithic composite with the transformer windings.
  • US 5 435 903 A shows a transformer core, which is produced by the deposition of amorphous soft magnetic layers and electrically insulating separation layers.
  • the object of the invention is therefore to provide transformer cores and transformer sheets and a method for their production, with which the production of transformer cores is comparatively facilitated.
  • This object is achieved with the transformer core specified above according to the invention in that a plurality of said soft magnetic layers and at least separating layers lying between them form a monolithic composite.
  • a monolithic composite in the sense of the invention thus means an intimately interconnected layer sequence which has at least two soft magnetic layers and at least one separating layer therebetween. Of course, the composite may also have more than these three layers.
  • the individual composites can also be processed as transformer sheets, with a plurality of said soft magnetic layers forming a monolithic composite at least with the separating layers lying between them. Again, it is particularly advantageous if just as many soft magnetic layers are produced as separating layers.
  • the monolithic composites are produced by the aforementioned method for producing a transformer sheet or a transformer core, in which a soft magnetic layer of an electrically conductive core material with an amorphous and / or nanocrystalline microstructure is electrochemically deposited on a base body. An electrically insulating separating layer is produced on the soft magnetic layer. Then a starting layer for a renewed electrochemical coating is then produced, then a further soft magnetic layer after the already mentioned method step and a further separating layer after the likewise described method step. This is repeated until the transformer sheet has reached the intended thickness.
  • a composite is thus produced by the sequence of electrochemical coating steps, so that the layers grow on each other and thus creates an intimate connection.
  • a transformer sheet can be produced which has a sufficient thickness for the further handling steps. This facilitates the manufacture of transformer cores themselves, as the brittle material is easier to handle when it is in a greater thickness.
  • the layers of as Composite manufactured transformer sheets simplified because fewer of these thicker transformer sheets must be laminated to the transformer core.
  • the advantage of using amorphous transformer cores or transformer plates is that they advantageously produce only small losses when used in the transformer. This is due to the low coercive field strength H C , so that hysteresis losses during remagnetization can be kept low.
  • an amorphous structure of the soft-magnetic layers it is not possible to detect formation of structure grains. This is because the glass-forming alloying portion results in a vitreous structure, so that the order of the atoms is stochastic like a liquid.
  • individual grains can be recognized whose size, however, is in the nanometer range, ie smaller than 100 nm, preferably even smaller than 10 nm.
  • the transition between an amorphous and nanocrystalline structure of the microstructure is fluid, although crystalline regions of the microstructure with dimensions in the nanometer range may also be present within an amorphous matrix surrounding them.
  • the transformer core or the transformer sheet (or the sheets in a layered transformer core) have soft magnetic layers whose thickness is between 2 and 100 ⁇ m.
  • the separating layers follow one another rapidly in the sequence of layers, which advantageously results in the eddy current losses in the transformer sheet minimize.
  • the formation of eddy currents is namely prevented by the electrically insulating separation layers or at least contained.
  • the separating layers can advantageously have a thickness of 0.1 to 1 ⁇ m. This thickness is sufficient to achieve sufficient electrical insulation between the adjacent soft magnetic layers.
  • the monolithic layer composites produced can advantageously have a thickness between 0.2 and 0.6 mm. This thickness is sufficient for the composites to have sufficient handling stability during the stacking of the transformer core from individual transformer laminations.
  • the separating layers and / or the starting layers lying between the separating layers and the soft magnetic layers are doped with nanoparticles for electrochemical deposition, like the relevant layer into which they are incorporated are electrically conductive or electrically insulating.
  • the chemical elements that make up the nanoparticles are selected in such a way that their incorporation into the matrix of the respective layer causes mechanical residual stresses in the respective layer due to atomic radii deviating from the layer material.
  • the mechanical stresses advantageously cause magnetic anisotropies. These anisotropies may be due to the location of the doping z. B. be influenced in lines or strip shape.
  • the position of the doping can be influenced by introducing the nanoparticles only partially into the layer. This can be achieved by not depositing the nanoparticles together with the metal to be deposited (dispersion with the electrolyte), but instead applying them to the substrate in a separate coating step become. This coating step must take place before the electrochemical coating and can be done, for example, by cold gas spraying of the particles used.
  • the generated mechanical stresses have a positive effect on the magnetization losses in the transformer sheet.
  • This can be described as a model as follows.
  • the mechanical stresses in the magnetically active layer lead to the retention of the so-called Bloch walls (these are the partitions of the white areas). Due to the immobility of the Bloch walls, the magnetic moments of entire white areas are reversed when an external magnetic field is applied.
  • Bloch walls these are the partitions of the white areas. Due to the immobility of the Bloch walls, the magnetic moments of entire white areas are reversed when an external magnetic field is applied.
  • the magnetic field of the material of the transformer core changes more.
  • the greater change in the magnetic field induces greater energy in the secondary coil of the transformer. This advantageously reduces the loss of magnetization and increases the relative permeability number.
  • an electrically conductive material is provided in the transformer sheet or the transformer core as the starting layer for electrochemical coating between the separation layers and the soft magnetic layers.
  • the conductive material is necessary in order to again be able to deposit a layer of the soft magnetic material on the electrically insulating separating layer. Since the separation layer itself can not serve as an electrode for the deposition of layer material, the application of the starting layer, for example by means of thermal Spraying or PVD process upstream of the electrochemical coating step.
  • the already-described mechanism of generating residual stresses can be achieved as the material of the transformer core heats up during operation. This is due to the fact that the heating during operation of the transformer core is greater than during its production, for example by means of electrochemical deposition and cold gas spraying. Here is another benefit of using cold gas spraying. This means that the layers of the transformer core or transformer sheet can be largely without residual stresses and then arise during operation of the transformer by heating it. According to the mechanism already described above (use of particles with different atomic radii), the magnetization losses can advantageously be reduced and the relative permeability number increases.
  • the soft magnetic layers and / or lying between the separation layers and the soft magnetic layers start layers for electrochemical deposition are doped with hard magnetic particles, wherein the magnetic field with respect to its field line at least substantially on the planned field line course in the transformer core or transformer sheet is aligned.
  • This can be advantageously stabilized in the operation of the transformer, the required field line profile of the magnetic field to be generated.
  • the magnetic properties of the resulting composite material between those of an amorphous layer and those of a nanocrystalline Set metal This applies to the electrochemically deposited matrix in which the magnetic particles are incorporated.
  • a subsequent heat treatment of the amorphous material with which normally amorphous microstructural orders can be converted into nanocrystalline can be saved.
  • the adjustment of the microstructure of the matrix between amorphous and nanocrystalline is advantageously much more accurately possible by means of the incorporated particles. It can then be further displaced by a heat treatment in the direction of nanocrystalline structural orders.
  • a more effective use of material or a lesser amount of cooling is required.
  • the object stated above is also achieved by a method for producing a transformer sheet or a transformer core consisting of a package of transformer laminations, in which a soft magnetic layer of an electrically conductive core material with an amorphous and / or transformer sheet is produced on a base body with an amorphous and / or or nanocrystalline microstructure is deposited electrochemically. An electrically insulating separating layer is then produced on this soft magnetic layer. Then, a starting layer for the electrochemical coating, a further soft magnetic layer after the already mentioned method step and a further separating layer after the already mentioned method step are produced repeatedly. This is repeated until the transformer sheet has the intended thickness has reached.
  • This method is advantageous for the production of transformer plates or transformer cores in the manner already described above, which have the advantages already described.
  • the electrochemical manufacturing method advantageously allows the production of extremely thin layers, so that the soft magnetic layers and the separating layers ensure effective prevention of eddy current losses.
  • the transformer sheets produced according to the invention are easier to process, since the thicknesses of the sheets produced can be selected independently of the small thickness of the individual soft magnetic layers.
  • the respective starting layers for the electrochemical coating are required because the separation layers due to their effect in the transformer plate (prevention of eddy current losses) must be electrically insulating. However, these are therefore not suitable for a further electrochemical deposition step. This can only take place if a starting layer for the electrochemical coating is again applied to the electrically insulating separating layers.
  • the coating with the soft magnetic layer by a reverse pulse plating takes place.
  • This per se known electrochemical deposition method involves the insertion of pulsed Abscheideströmen for the coated workpieces.
  • the current pulses alternately change from cathodic to anodic currents, wherein the cathodic deposition must predominate on the workpiece as compared to the anodic dissolution to come to a deposition.
  • the reverse pulse plating is particularly advantageous for the deposition of uniform layer thicknesses.
  • At least one soft magnetic element in particular one or more of the elements Fe, Si, Ni or Co, and at least one glass-forming element, in particular P and / or B, are jointly deposited as a soft magnetic layer.
  • the soft magnetic elements serve advantageously to produce a soft magnetic layer, wherein the glass formers are added to ensure the formation of an amorphous microstructure during the electrochemical deposition.
  • An embodiment of the method according to the invention provides that the layers produced in each case correspond exactly to the longitudinal section of the transformer core to be produced with a cutting plane aligned parallel to the course of the layer.
  • the orientation of the layers is exactly in the direction that is usually used to laminate transformer sheets.
  • the layer planes are thus such that the two center axes of the transformer windings lie in one of these layer planes. This is advantageous because the expansion of the transformer core is the lowest across these layer planes and therefore the transformer core or, correspondingly, the transformer plates can be made with a minimum number of individual layers.
  • the deposition of the starting layer takes place by atomization of powder, by thermal spraying (in particular cold gas spraying) or by PVD coating of an electrically conductive material.
  • the electrically conductive material is applied to the previously applied electrically insulating release layer by atomizing, thermal spraying or PVD coating.
  • This coating step can be carried out until the starting layer has the required thickness for a subsequent electrochemical coating.
  • the thermal spraying since this method allows comparatively high deposition rates.
  • the cold gas spraying can be used, because this goes largely without a thermal load of the deposited particles of the starting layer and the substrate of Statte.
  • thermal spraying such as plasma spraying can also be used to achieve a targeted transformation of the deposited amorphous structure into a nanocrystalline structure by the thermal energy introduced in this way.
  • the deposition of the starting layer can also take place in two steps.
  • thermal spraying or PVD coating with the material of the starting layer and with an amount that is not sufficient for a galvanic deposition can be carried out as an intermediate step electrochemical deposition of the electrically conductive material by an electroless method until the starting layer has reached the required thickness.
  • even low layer thicknesses or not yet closed layers on the electrically insulating separating layer are sufficient for currentless deposition.
  • the electrically conductive material with which the starting layer is produced contains only chemical elements of the soft magnetic layer. This has the advantage that the starting layer after completion of the overlying soft magnetic layer so to speak merges with this and no longer appears as a separate layer in appearance. This will influence the product to be produced Product of transformer core or transformer sheet.
  • a particular embodiment of the method according to the invention is obtained when a base body made of a soft magnetic, electrically conductive material, in particular with an amorphous and / or nanocrystalline microstructure is used.
  • the base body which is always required for an electrochemical coating to provide a substrate for coating, can according to this advantageous embodiment support the function of the transformer sheet or of the transformer core in the same way as the subsequently produced soft magnetic layers.
  • the base body consists of an amorphous and / or nanocrystalline structure, a performance comparable to the soft magnetic layers can be achieved.
  • soft magnetic nanoparticles which can be incorporated into the soft magnetic layers and / or starter layers in order to influence the microstructure there in the manner already described.
  • the microstructure can be influenced in such a way that a specific ratio of the proportions of amorphous and / or nanocrystalline microstructures can be set. This advantageously eliminates post-treatment of the layers for adjusting the microstructure (heat treatment), which, however, can optionally be carried out to correct the properties of the layers produced.
  • the incorporation of soft magnetic nanoparticles can advantageously also be promoted in that they are deposited in a magnetic field or the substrate is magnetized during the deposition. In this way, the incorporation rates of nanoparticles can be influenced, wherein in addition to the concentration of the nanoparticles to be incorporated in the electrolyte, a parameter for adjusting the particle concentration available stands. This can be used in particular to shift a rate of incorporation to higher values, since the concentration of nanoparticles that can be dispersed in the electrolyte is limited (otherwise the nanoparticles precipitate out of the suspension again).
  • hard-magnetic particles are incorporated into the soft-magnetic layers and / or the starting layers, during the deposition process the forming layer being exposed to a magnetic field whose field line profile at least substantially corresponds to the planned field line profile in the transformer core to be produced.
  • the hard magnetic particles By means of the deposition process, the hard magnetic particles, the magnetization of which does not change during operation of the transformer, are fixed in a certain orientation in the surrounding matrix of the structure, for which reason the magnetic field generated by them during operation of the transformer superimposes the magnetic field due to the processes taking place in the transformer , As a result, the magnetic field in the transformer is stabilized and deviations from the desired field line course are attenuated. Furthermore, it is advantageously possible to carry out a targeted correction of the magnetic field generated during operation in the transformer. In order to accomplish this, deviations must be intentionally provided for the magnetic field which is used during the deposition process of the forming layers, which produces an orientation of the hard magnetic particles with intended deviations from the planned field line course in the transformer core to be produced.
  • the deviating magnetic field then corrects the magnetic field actually produced in the transformer core in the desired manner, whereby, for example, unwanted deviations of the actually generated field line profile of a transformer from the desired field line course can be corrected.
  • nanoparticles are incorporated in the starting layers and / or in the separating layers, which, like the relevant layer in which they are incorporated, are electrically conductive or electrically insulating.
  • the chemical elements of the nanoparticles are selected such that their incorporation into the matrix of the respective layer by means of atomic radii deviating from the layer material lead to mechanical residual stresses in the relevant layer.
  • an electrically conductive material whose thermal expansion coefficient differs by at least 10 and at most 30% from that of the soft magnetic layers can advantageously be deposited for the starting layers. This also makes it possible to generate residual stresses during operation due to the heating of the transformer core, which positively influence the magnetic behavior of the transformer in the manner already described.
  • the production of a transformer sheet is then carried out by a sequence of the described basic steps simultaneously on both sides in order to halve the required coating time.
  • the basic body is first produced by phosphating with an electrical insulation layer. Depending on the material of the base body, for example, iron phosphate or zinc phosphate is formed.
  • a starting layer is applied to the electrically insulating separating layer of phosphate for a subsequent electrochemical deposition. This can be done by a first intermediate step, in which conductive iron or nickel is applied in the form of powders by atomization or cold gas spraying.
  • the metal can also be applied by sputtering or vapor deposition, which is worthwhile, above all, for small workpieces.
  • iron, iron phosphorous, nickel or an iron-nickel alloy is electrodeposited by electroless deposition until the layer so formed has received sufficient thickness for a subsequent electrodeposition step (i.e., applying a deposition current).
  • the galvanic deposition of an amorphous iron-phosphorus alloy or a nickel-iron alloy, which forms the soft magnetic layer This can be done in detail as follows.
  • the base body used is a degreased, cleaned and activated metal foil of, for example, 20 ⁇ m thick, which consists of iron, nickel or a nickel-iron alloy. This is phosphated on both sides by dipping, spraying or electrochemical. The phosphating is carried out with an iron phosphate or zinc phosphate-containing solution and subsequent Drying at below 100 ° C.
  • the chemicals required for this purpose can be obtained, for example, from SurTec.
  • the phosphating may also be cathodic using an electrolyte which may contain one or more of the following types of ions: Zn 2+ , Ca + , PO 4 3+ , NO 3 - or ClO 3 - or F - .
  • This electrochemical deposition can be carried out at a temperature of 25 ° C a pH between 1 and 4 and a current density between 5 and 250 mA / cm 2 .
  • By varying the current density and the other conventional deposition parameters it is possible to produce different layer thicknesses of up to 100 ⁇ m (preferably 1 to 20 ⁇ m).
  • the layer can also be produced with pores, which in a next step serve to take up nickel, iron or nickel iron particles.
  • the step of coating with said particles is preferably accomplished by atomization or by cold gas spraying. This is done by an electroless deposition of an iron phosphorus alloy or nickel with a layer thickness of preferably 0.3 microns.
  • the electrolyte used contains iron sulfate, sodium hypophosphite, potassium sodium tartrate, boric acid and small amounts of sugar acid.
  • a pH of 8 to 11.5 is set with 15% sodium hydroxide solution, the electroless deposition process being carried out at 50 to 85 ° C. At 80 ° C and a pH of 10.5 to obtain an iron phosphorus alloy with 94.5 wt .-% iron and 5.5 wt .-% phosphorus.
  • an electrolyte containing nickel sulfate, sodium glycolate, and sodium hypophosphite may be used.
  • sodium hydroxide solution With sodium hydroxide solution, the pH to 4 set to 5.
  • the electroless deposition is carried out at a bath temperature between 90 and 95 ° C.
  • the electrochemical deposition of the amorphous iron-phosphorus or nickel-iron alloy can now take place.
  • This electrochemical deposition of the soft magnetic layer is carried out with deposition baths consisting of aqueous solutions of iron (II) salts.
  • iron (II) salts For example, iron (II) chloride, iron (II) sulfate, iron (II) fluoroborate or iron (II) sulfamate can be used.
  • a hypophosphite or orthophosphite is used (for example, sodium hypophosphite or sodium orthophosphite). This produces the desired iron-phosphorus alloys in the layer.
  • soluble anodes of iron preferably of pure iron, or insoluble anodes, for example of platinized titanium
  • the deposition takes place at temperatures between 40 and 70 ° C.
  • the selected current density is 10 to 100 A / dm 2 .
  • the deposition process can be carried out by a DC process or particularly advantageously by reverse pulse plating.
  • an electrolyte consisting of, for example, nickel chloride, iron chloride, sodium chloride, sodium saccharin, sodium lauryl sulfate and boric acid may be used.
  • the deposition takes place at 30 ° C. and a pH of 3 with a current density of 0.5 to 8 A / dm 2 .
  • the anodes used are nickel or iron anodes. After reaching the required layer thicknesses (eg 0.23 mm), the phosphating process step already described above is repeated.
  • transformer sheets are produced by the method described above, the required shape can be achieved in various ways. Either the transformer sheet is produced over a large area as a semifinished product, wherein the known forms for the transformer sheets in the form of an E and I are produced by separating the transformer sheet (for example punching). But it is also possible to bring the base body in the required form of the transformer sheet and then to coat, the transformer sheet is then formed immediately in its required shape. In order to guarantee the dimensional accuracy, in particular a coating after the reverse pulse plating is particularly advantageous. In this way, transformer sheets in all common configurations (M, EI, UI and LL) as well as sheet metal strips for the production of cut cores or even annular transformer sheets for the direct, gapless production of toroidal cores can be produced. Selected intermediates of the method exemplified above are described in U.S.P. FIGS. 4 to 7 described in more detail.
  • FIG. 1 shows a galvanic bath 11, which is suitable for coating a base body 12 of a transformer sheet.
  • This body is annular and therefore already has the shape of the transformer sheet to be installed.
  • the main body 12 should be coated on both sides, which is why counter electrodes 13 are arranged on both sides and correspond in their extent to the base body 12 in order to produce the most uniform possible electric field in the electrolyte 14 used.
  • the base body 12, which forms the working electrode, and the counter-electrodes 13 are connected to one another via a controller 15, it being possible to control the deposition current via the controller 15.
  • FIG. 2 One possible control of the separation stream is in FIG. 2 shown.
  • the deposition current density i on This is according to FIG. 2 considered over time t.
  • cathodic current pulses having a deposition current density i c and anodic current pulses having a deposition current density i a are generated.
  • the respective associated pulse length t c and t a is to be considered in the leadership of the reverse pulse Platings that a total of a layer structure must be made. This presupposes that the integrals of the current density i over the time t Q c of the cathodic current pulse are greater than Q a of the anodic current pulse.
  • FIG. 3 Due to the current flow, a layer growth can be generated, as in FIG. 3 is shown.
  • the irregularities 16 during cathodic layer growth, represented by the contour 17, can be largely corrected, since in the subsequent anodic current pulse the irregularity 16 is degraded disproportionately and the contour 18 is present after the anodic current pulse.
  • the anodic dissolution of the material is less than the cathodic growth, which is why deposited material remains on the base body 12.
  • FIG. 3 shown greatly exaggerated to visualize the course of the contours 17, 18.
  • FIGS. 4 to 7 represented intermediates of the method according to the invention can be produced with the above-mentioned examples of the method according to the invention.
  • the main body 12 is shown as a foil. This is already provided on both sides with an electrically insulating separation layer 19 by phosphating.
  • On the release layer 19 further particles 20 are applied to a start layer 21, which FIG. 5 can be removed.
  • the particles 20 can be, for example, by atomizing are applied to the release layer 19 and are in FIG. 5 no longer recognizable, since the starting layer 21 consists of the same material as the particles 20.
  • electrochemical coating on the starting layer 21 with the material of soft magnetic layers 22 see FIG FIG. 6 ) respectively. These ensure the function of the transformer core.
  • FIG. 7 It is shown how, in each case, a separation layer 19 was again formed on the base body after the application of the soft magnetic layers 22 on both sides, and in each case particles 20 for a starting layer were deposited on the separation layers 19 thus formed.
  • the following can be added to FIG. 5 Repeated steps are repeated as often as desired until the desired thickness of the transformer plate or the desired shape of the transformer core is reached.
  • the starting layers 19 used can in this embodiment be formed, for example, from copper. Thus, there is always a layer of copper between the separating layers 19 and the soft magnetic layers 22 in the direction of the layer formation, which corresponds to the in FIG. 7 causes layer structure.
  • FIG. 6 a layer structure is shown, in which the particles 20 are made of the same material as the soft magnetic layer 22. After application of the particles 20 then forms a layer structure, the in FIG. 5 is similar. However, the separation layers 21 in the layer composite according to FIG. 6 no longer recognizable, since these together with the soft magnetic layers 22 result in a single microstructure.
  • FIGS. 8 and 9 It can be seen schematically how the incorporation of particles in different layers of the layer composite according to the invention for transformer sheets can be done.
  • the soft magnetic layer 22 made of nickel iron nanoparticles 23 are also made of nickel iron.
  • the soft magnetic layer 22, which grows amorphous during electrochemical coating, can thus be provided in a targeted manner with a nanocrystalline structure.
  • the nanoparticles 23 themselves may also be formed amorphous or crystalline. In the event that the nanoparticles 23 themselves are crystalline (as in FIG FIG.
  • FIG. 8 represented by the nanoparticles further grains in the amorphous matrix of the layer 22, so that in FIG. 8 represented contours of the particles 23 also represent grain boundaries. If the particles 23 themselves were amorphous, they would fuse with the amorphous matrix of the soft magnetic layer 22 and would be virtually invisible.
  • nanocrystalline particles 25 of a FeCuNbSiB alloy or of amorphous iron alloys may be introduced into the starting layer 21 of metal, which may consist for example of cobalt. These particles are dispersed in the electroless plating deposition electrode and then co-deposited with the starting layer 21.
  • the concentration of the particles 25 can be adjusted by the temperature, the speed of movement of the electrolyte (agitation) and the composition of the electrolyte.
  • nanoparticles 26 of Al 2 O 3 or CrO 3 can be introduced into the separating layer 19 (cf. FIG. 9 ). These nanoparticles 26 also lead to residual stresses and therefore improve the manufactured transformer sheet in the manner already mentioned above.
  • the nanoparticles 26 can either be admixed to the electrolyte during an electrochemical phosphating or a precursor during the phosphating by dipping or spraying and are then automatically incorporated into the applied layer.
  • Anisotropy of the microstructure due to different coefficients of expansion can also be produced by using a suitable material such as gold, silver, copper or aluminum as starting layer 21. These metals generate the residual stresses when heating the transformer sheet by their deviating from the adjacent layers expansion coefficient.
  • FIG. 9 Also shown is the introduction of magnetic particles 27, which may also be designed as nanoparticles. Schematically illustrated is a magnetic field 28, which has the magnetic particle 27 and which is aligned in the direction of the desired field line course in the soft magnetic layer 22.
  • a magnetic field 28 which has the magnetic particle 27 and which is aligned in the direction of the desired field line course in the soft magnetic layer 22.
  • all known hard magnetic alloys can be used.

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  • Manufacturing & Machinery (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Dispersion Chemistry (AREA)
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  • Manufacturing Cores, Coils, And Magnets (AREA)

Claims (20)

  1. Tôle de transformateur, ayant une couche (22) à magnétisme doux d'un matériau de noyau conducteur de l'électricité, de structure amorphe et/ou nanocristalline, qui est revêtue d'une couche (19) de séparation d'un matériau isolant du point de vue électrique,
    caractérisée en ce que
    plusieurs desdites couches (22) à magnétisme doux forment un composite monolithique au moins avec les couches (19) de séparation se trouvant entre elles.
  2. Tôle de transformateur suivant la revendication 1,
    caractérisée en ce que
    celle-ci a une épaisseur comprise entre 0,2 et 0,6 mm.
  3. Noyau de transformateur, ayant des couches (22) à magnétisme doux d'un matériau de noyau conducteur de l'électricité, de structure amorphe et/ou nanocristalline, qui sont séparées les unes des autres par des couches (19) de séparation d'un matériau isolant du point de vue électrique, dans lequel plusieurs desdites couches (22) à magnétisme doux forment un composite monolithique au moins avec les couches (19) de séparation se trouvant entre elles,
    caractérisé en ce que
    celui-ci est constitué d'un paquet de tôles, les tôles de transformateur étant constituées chacune entièrement d'un composite monolithique de couches (22) à magnétisme doux et de couches (19) de séparation.
  4. Noyau de transformateur ou tôle de transformateur suivant l'une des revendications précédentes,
    caractérisé en ce que
    les couches (22) à magnétisme doux ont une épaisseur de 2 à 100 µm.
  5. Noyau de transformateur ou tôle de transformateur suivant l'une des revendications précédentes,
    caractérisé en ce que
    les couches (19) de séparation ont une épaisseur de 0,1 à 5 µm.
  6. Noyau de transformateur ou tôle de transformateur suivant l'une des revendications 1 à 5,
    caractérisé en ce que
    les couches (19) de séparation et/ou les couches (21) de départ, se trouvant entre les couches (19) de séparation et les couches (22) à magnétisme doux, sont, pour un dépôt électrochimique, dopées par des nanoparticules (25), qui, comme les couches concernées dans lesquelles elles sont incorporées, sont conductrices de l'électricité ou isolantes du point de vue électrique et dont les élément chimiques sont choisis de manière à ce que leur incorporation dans la matrice de la couche concernée provoque, par des rayons atomiques s'écartant du matériau de la couche, des contraintes mécaniques propres dans la couche concernée.
  7. Noyau de transformateur ou tôle de transformateur suivant l'une des revendications 1 à 6,
    caractérisé en ce qu'
    il est prévu, comme couches (21) de départ, pour un revêtement électrochimique, entre les couches (19) de séparation et les couches (22) à magnétisme doux, un matériau conducteur de l'électricité, dont le coefficient de dilatation thermique se distingue d'au moins 10% et d'au plus 30% de celui des couches à magnétisme doux.
  8. Noyau de transformateur ou tôle de transformateur suivant l'une des revendications 1 à 7,
    caractérisé en ce que
    les couches (22) à magnétisme doux et/ou les couches 21 de départ se trouvant entre les couches (19) de séparation et les couches (22) à magnétisme doux sont, pour un dépôt électrochimique, dopées par des particules (27) à magnétisme dur, dans lequel leur champ magnétique, en ce qui concerne son tracé des lignes de champs, est dirigé, au moins sensiblement, sur le tracé prévu des lignes de champs dans le noyau du transformateur ou dans la tôle de transformateur.
  9. Procédé de fabrication d'une tôle de transformateur ou d'un noyau de transformateur constitué d'un paquet de tôles de transformateur, dans lequel, pour la fabrication de la tôle de transformateur ou des tôles de transformateur,
    • on dépose électrochimiquement, sur un corps (12) de base, une couche (22) à magnétisme doux en un matériau conducteur de l'électricité, qui reçoit une structure amorphe et/ou nanocristalline,
    • on produit, sur la couche (22) à magnétisme doux, une couche (19) de séparation isolante du point de vue électrique et
    • de manière répétée, on produit une couche (21) de départ pour le revêtement électrochimique, une autre couche (22) à magnétisme doux après le stade de procédé mentionné ci-dessus et une autre couche (19) de séparation après le stade de procédé mentionné ci-dessus, jusqu'à ce que la tôle de transformateur ait atteint l'épaisseur prévue.
  10. Procédé suivant la revendication 9,
    caractérisé en ce que
    le revêtement, par la couche (22) à magnétisme doux, s'effectue par un reverse pulse plating.
  11. Procédé suivant l'une des revendications 9 ou 10,
    caractérisé en ce que
    l'on dépose conjointement, comme couche (22) à magnétisme doux, au moins un élément à magnétisme doux, notamment ou plusieurs des éléments Fe, Ni ou Co, et au moins un élément formant un verre, notamment P et/ou B.
  12. Procédé suivant l'une des revendications 9 à 11,
    caractérisé en ce que
    des couches produites respectivement correspondent exactement à la coupe longitudinale du noyau de transformateur à fabriquer, ayant un plan de coupe dirigé parallèlement à l'étendue de la couche.
  13. Procédé suivant l'une des revendications 9 à 12,
    caractérisé en ce que
    le dépôt de la couche (21) de départ s'effectue par atomisation de poudre par pulvérisation thermique ou par dépôt PVD d'un matériau conducteur de l'électricité.
  14. Procédé suivant la revendication 13,
    caractérisé en ce qu'
    après l'atomisation, la pulvérisation thermique ou le dépôt PVD, on effectue un dépôt électrochimique sans courant du matériau conducteur de l'électricité jusqu'à ce que la couche (21) de départ ait atteint l'épaisseur nécessaire.
  15. Procédé suivant l'une des revendications 13 ou 14,
    caractérisé en ce que
    le matériau conducteur de l'électricité contient seulement des éléments chimiques de la couche (22) à magnétisme doux.
  16. Procédé suivant l'une des revendications 9 à 15,
    caractérisé en ce que
    l'on utilise un corps de base en un matériau à magnétisme doux conducteur de l'électricité, ayant notamment une structure amorphe et/ou nanocristalline.
  17. Procédé suivant l'une des revendications 9 à 16,
    caractérisé en ce que
    l'on incorpore des nanoparticules (23) à magnétisme doux dans les couches (22) à magnétisme doux et/ou dans les couches (21) de départ.
  18. Procédé suivant l'une des revendications 9 à 17,
    caractérisé en ce que
    l'on incorpore des particules (27) à magnétisme dur dans les couches (22) à magnétisme doux et/ou dans les couches de départ, dans lequel, pendant l'opération de dépôt, on soumet la couche qui se forme à un champ magnétique, dont le tracé des lignes de champ correspond au moins sensiblement au tracé prévu des lignes de champ dans des noyaux de transformateur à fabriquer.
  19. Procédé suivant l'une des revendications 9 à 18,
    caractérisé en ce que
    l'on incorpore, dans les couches (21) de départ et/ou dans les couches (19) de séparation, des nanoparticules (26), qui, comme les couches concernées dans lesquelles elles sont incorporées, sont conductrices de l'électricité ou isolantes du point de vue électrique et dont et les élément chimiques sont choisis de manière à ce que leur incorporation dans la matrice de la couche concernée donne, par des rayons atomiques s'écartant du matériau de base, des contraintes mécaniques propres dans la couche concernée.
  20. Procédé suivant l'une des revendications 9 à 19,
    caractérisé en ce que
    l'on dépose, comme couches (21) de départ, un matériau conducteur de l'électricité, dont le coefficient de dilatation thermique se distingue d'au moins 10% et d'au plus 30% de celui des couches à magnétisme doux.
EP10749632.5A 2009-09-29 2010-08-25 Noyau de transformateur ou tôle de transformateur avec une structure amorphe et/ou nanocristalline et procédé pour sa fabrication Not-in-force EP2483898B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102009048658A DE102009048658A1 (de) 2009-09-29 2009-09-29 Transformatorkern oder Transformatorblech mit einer amorphen und/oder nanokristallinen Gefügestruktur und Verfahren zu dessen Herstellung
PCT/EP2010/062394 WO2011039001A1 (fr) 2009-09-29 2010-08-25 Noyau de transformateur ou tôle de transformateur avec une structure amorphe et/ou nanocristalline et procédé pour sa fabrication

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EP2483898A1 EP2483898A1 (fr) 2012-08-08
EP2483898B1 true EP2483898B1 (fr) 2018-05-02

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GB2540150B (en) 2015-07-06 2020-01-08 Dyson Technology Ltd Rare earth magnet with Dysprosium treatment
DE102016102386A1 (de) * 2016-02-11 2017-08-17 Vacuumschmelze Gmbh & Co. Kg Hybridmagnet und Verfahren zu dessen Herstellung
SI3503134T1 (sl) 2017-12-20 2020-08-31 Bertram Ehmann Držalna naprava za držanje mehkomagnetnega lameliranega jedra transformatorja in pa transformator
ES2876373T3 (es) 2017-12-20 2021-11-12 Bertram Ehmann Procedimiento y producto semiacabado para la fabricación de al menos una sección de paquete de un componente magnético suave
CN111321408A (zh) * 2020-03-02 2020-06-23 中国科学院宁波材料技术与工程研究所 一种多界面非晶纳米晶电磁屏蔽复合材料

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JPS6039160B2 (ja) 1982-07-22 1985-09-04 新日本製鐵株式会社 絶縁性、耐食性の優れた磁性アモルフアス合金材料
DE3346659A1 (de) * 1983-12-23 1985-07-04 Standard Elektrik Lorenz Ag, 7000 Stuttgart Induktives bauelement
EP0422760A1 (fr) * 1989-10-12 1991-04-17 Mitsubishi Rayon Co., Ltd Alliage amorphe et procédé pour sa fabrication
JPH04345007A (ja) * 1991-05-22 1992-12-01 Mitsubishi Rayon Co Ltd 複合磁性膜およびその製法並びにそれを用いたコア
FR2842018B3 (fr) * 2002-07-02 2004-06-04 Memscap Micro-composant incluant un element inductif du type inductance ou transformateur
CN1877756A (zh) * 2005-06-10 2006-12-13 富准精密工业(深圳)有限公司 磁性粉体
CA2576752A1 (fr) 2007-02-02 2008-08-02 Hydro-Quebec Feuille metallique en fer amorphe fe 100-a-bpamb et sa methode de preparation et d'utilisation

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WO2011039001A1 (fr) 2011-04-07
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