EP3503139B1 - Verfahren und halbzeug zum herstellen von wenigstens einem paketabschnitt eines weichmagnetischen bauteils - Google Patents

Verfahren und halbzeug zum herstellen von wenigstens einem paketabschnitt eines weichmagnetischen bauteils Download PDF

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EP3503139B1
EP3503139B1 EP17209155.5A EP17209155A EP3503139B1 EP 3503139 B1 EP3503139 B1 EP 3503139B1 EP 17209155 A EP17209155 A EP 17209155A EP 3503139 B1 EP3503139 B1 EP 3503139B1
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European Patent Office
Prior art keywords
composite
film
film composite
amorphous
soft magnetic
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German (de)
English (en)
French (fr)
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EP3503139A1 (de
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Bertram Ehmann
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Individual
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Priority to PL17209155T priority Critical patent/PL3503139T3/pl
Priority to ES17209155T priority patent/ES2876373T3/es
Priority to EP17209155.5A priority patent/EP3503139B1/de
Publication of EP3503139A1 publication Critical patent/EP3503139A1/de
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
    • H01F41/0226—Manufacturing of magnetic circuits made from strip(s) or ribbon(s) from amorphous ribbons
    • 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
    • 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
    • H01F1/15391—Elongated structures, e.g. wires
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/04—Cores, Yokes, or armatures made from strips or ribbons
    • 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
    • H01F1/15383—Applying coatings thereon
    • 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
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F2027/348—Preventing eddy currents

Definitions

  • the invention relates to a method for producing at least one package section of a soft magnetic component of an electrical machine, a semi-finished product for producing at least one package section of a soft magnetic component of an electrical machine, a package section for a soft magnetic component of an electrical machine and a soft magnetic component for an electrical machine .
  • Transformers convert an AC input voltage into an AC output voltage that differs from the AC input voltage. Transformers are used, for example, to convert voltage in energy supply systems and in electrical devices.
  • a transformer For each phase of the input AC voltage to be converted, a transformer has a primary coil and a secondary coil, which are arranged on a common transformer core made of ferromagnetic materials or ferrites.
  • the transformer core bundles the magnetic flux in connection with the coils and increases the inductance and the magnetic flux density of the transformer.
  • the transformer core can have a laminated core made up of several transformer laminations that are electrically insulated from one another. This allows eddy current losses of the transformer to be reduced during voltage conversion.
  • a three-phase transformer has a magnetically soft transformer core which has three legs running parallel to one another and two yokes connected to the legs at each end. There is a primary coil and on each leg arranged a secondary coil of the same current phase.
  • One of the yokes can be monolithically connected to the three legs, as a result of which an E-shaped section of the transformer core is formed. After the coils have been arranged on the legs, the second yoke can be connected to the free ends of the legs.
  • DE 10 2009 048 658 A1 discloses a transformer core having soft magnetic layers of an electrically conductive core material with an amorphous and / or nanocrystalline microstructure, which are separated from one another by separating layers of an electrically insulating material.
  • the transformer core thus consists of a laminated core, the transformer laminations each consisting entirely of a monolithic composite of soft magnetic layers and separating layers.
  • a soft magnetic layer made of an electrically conductive core material is deposited electrochemically on a base body.
  • An electrically insulating separating layer is produced on the soft magnetic layer.
  • At least one soft magnetic element in particular one or more of the elements iron (Fe), nickel (Ni) or cobalt (Co), and at least one glass-forming element, in particular phosphorus (P) and / or boron (B), are used as the soft magnetic layer deposited
  • EP 2 139 011 A1 discloses a method which laminates several soft magnetic tapes to one another in a materially bonded manner.
  • the formation of a transformer core using soft magnetic amorphous layers is associated with a reduction in the losses on the transformer core during its use in a transformer. This is due to the lower magnetic coercive field strength, so that hysteresis losses when magnetizing the transformer core can be kept small.
  • One object of the invention is to reduce the costs of producing soft magnetic components for energy-efficient electrical machines.
  • a semifinished product for the production of at least one package section of a soft magnetic component of an electrical machine can be produced relatively quickly compared to the prior art, in which, for example, the individual layers of a transformer core package are deposited one after the other, as is shown, for example, from DE 10 2009 048 658 A1 is known.
  • significantly more time has to be expended than in the steps described above but not yet according to the invention for manufacturing at least one package section of the soft magnetic component of the electrical machine. This makes these steps for the production of at least one package section of the soft magnetic component of the electrical machine significantly more cost-effective than the conventional production of a transformer core package.
  • a package section is to be understood as a section of the soft magnetic component in which at least two different layers are alternately stacked, whereby a layer composite is formed which is referred to as a package within the scope of the invention.
  • the electrical machine can be a stationary electrical machine, for example a transformer, a relay, a contactor, a choke coil, an ignition coil, an electricity meter or a controllable deflection magnet.
  • the soft magnetic component is designed as a soft magnetic core of the stationary electrical machine, which runs through at least one electrical coil of the stationary electrical machine.
  • the electric machine can be a rotating electric machine, for example an electric motor or an electric generator.
  • the soft magnetic component of the rotating electrical machine is designed as a rotor component or stator component.
  • the continuous production of the strip-shaped, soft magnetic film with an amorphous and / or nanocrystalline microstructure from an iron alloy, in particular an FeSiB alloy, using a casting process can be carried out more quickly than a conventional successive deposition of individual layers of a certain shape and size.
  • a melt is first produced from the iron alloy, for example using an induction melting furnace.
  • the melt can then be poured onto a rotating roller, where the melt is progressively cooled with the formation of the amorphous film or solidifies with the formation of the amorphous and / or nanocrystalline microstructure.
  • the amorphous film formed in this way can be pulled off the roller and, after any further processing and / or processing steps, wound up into a film roll.
  • the amorphous film can then be unreeled again for further process steps.
  • the amorphous film is produced continuously means, within the scope of the invention, that the amorphous film is not designed in a certain size and shape, which is adapted to a size and shape of a soft magnetic component to be produced, but as an elongated strip that is one May have a length of, for example, several 10,000 m.
  • the thickness of the amorphous film can, for example, be in a range from approximately 20 ⁇ m to approximately 60 ⁇ m.
  • the maximum width of the amorphous film can, for example, be in a range from approximately 180 mm to approximately 300 mm, in particular up to approximately 400 mm. With a thickness of approximately 25 ⁇ m, the length of the amorphous film can be, for example, 35,000 m.
  • the iron alloy preferably contains at least one soft magnetic element, in particular one or more of the elements Fe, silicon (Si), Ni or Co, and at least one glass-forming element, in particular P and / or B.
  • the elements that form glass when the abovementioned melt cools serve to form the amorphous and / or nanocrystalline microstructure of the film.
  • the continuous production of the strip-shaped film composite by continuously, in particular flat or local, cohesive connection of the amorphous film with at least one correspondingly produced further amorphous film can be carried out significantly faster than the conventional production of a special film composite by depositing individual layers, as is the case, for example DE 10 2009 048 658 A1 disclosed.
  • the two amorphous films can, for example, be unwound from different film rolls at the same time.
  • an adhesive can be continuously applied to at least one of the two unreeled foil sections to form the material bond between the amorphous foils during the further unwinding of the amorphous foils, for example by means of an application roller or by spraying on the adhesive or by continuous deposition, for example gas phase deposition or plasma-induced material deposition, in particular of aluminum oxide or the like.
  • the adhesive can alternatively be applied in dots or in lines.
  • the adhesive forms an adhesive layer between two adjacent amorphous foils of the foil composite, which can be electrically insulating in order to electrically separate the amorphous foils from one another. As a result, eddy current losses in an electrical machine with a correspondingly constructed soft magnetic component can be kept as low as possible.
  • the adhesive layer can produce little or no electrical insulation, and the electrical separation of the amorphous films from one another can take place in a different manner.
  • at least one main side of an amorphous foil can be treated, for example by a diffusion process or the like, in such a way that a section of the amorphous foil adjoining the main side has a reduced electrical level compared to the rest of the amorphous foil Has conductivity, which is used for electrical insulation between interconnected amorphous films.
  • another agent for example an oil
  • another agent can be applied continuously to at least one of the two unreeled foil sections which creates or strengthens an adhesion between the amorphous foils.
  • the agent can alternatively be applied punctiformly or in lines.
  • the material bond between the amorphous foils can be generated by at least one connecting side of at least one amorphous foil being heated at least in some areas before the amorphous foils are brought together and thereby partially melted, so that the melted material of this amorphous foil on the other amorphous foil solidifies and causes the material bond.
  • At least two strip-shaped, soft magnetic foils each with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy, are continuously produced using a casting process.
  • the amorphous film can also be connected to two or more, for example two to seven, further amorphous films, the film composite thereby having a corresponding number of film layers.
  • the film composite can then be reeled into a film composite roll in order to be available for further processing and / or processing steps.
  • a film composite with five layers of amorphous films with a respective thickness of approximately 25 ⁇ m can be produced, for example, with a length of approximately 7,000 m.
  • the thickness of the film composite can, for example, be in a range from approximately 40 ⁇ m to approximately 400 ⁇ m.
  • the film composite represents a first semifinished product, not according to the invention, for producing a soft magnetic component of an electrical machine.
  • At least one electrically insulating separating layer can be applied to the film composite over a continuous area at least on one side or formed on the film composite. This is particularly advantageous if the film composite is later to be connected to at least one correspondingly produced further film composite, since the film composites are then electrically separated from one another in order to reduce eddy current losses.
  • an electrically insulating adhesive can also be used to connect the film composites.
  • An electrically insulating separating layer can also be arranged on each side of the film composite. The film composite provided with the at least one separating layer can then be reeled into a film composite roll in order to be available for further processing and / or processing.
  • the film composite provided with the at least one separating layer represents a variant of the above-mentioned first semi-finished product.
  • the separating layer can for example be formed on one side of the film composite by treating the corresponding main side of the film composite, for example by a diffusion process or the like, in such a way that a the section of the film composite adjoining the main side has a reduced electrical conductivity compared to the rest of the film composite, which is used for electrical insulation between interconnected film composites.
  • the continuous application or formation of at least one electrically insulating separating layer on at least one side flat on or on the film composite can be carried out significantly faster than, for example, the deposition of separating layers DE 10 2009 048 658 A1 .
  • the application of the electrically insulating separating layer to the film composite can take place by means of a continuous material connection, for example using a sprayed-on adhesive or other adhesive, of the film composite with a film forming the separating layer.
  • the continuous application of the separating layer can alternatively be carried out by continuously applying an electrically insulating layer to the respective amorphous film, for example by means of an application roller or by spraying on the adhesive or by continuous deposition, e.g.
  • the electrically insulating separating layer can be formed on the film composite, for example, by continuous application, for example take place by means of an application roller or by spraying an insulation material on the film composite, which hardens as quickly as possible after its application to form the separating layer.
  • the separation layer can be formed on the film composite by treating a main side of the film composite as described above. The statements and configurations made here for the continuous application or formation of the separating layer can be transferred accordingly to the separating layers mentioned in the rest of the application.
  • an individual package section of the soft magnetic component of the electrical machine can be produced.
  • two or more package sections of the soft magnetic component of the electrical machine or even all package sections of the soft magnetic component of the electrical machine can be produced with the method according to the invention.
  • the entire soft magnetic component of the electrical machine can be produced with the method according to the invention.
  • At least one electrically insulating separating layer is continuously applied flatly on at least one side to each of the films or formed on each of the films.
  • the continuous application or formation of at least one electrically insulating separating layer at least on one side flat on or on the respective amorphous film can also be carried out significantly faster than, for example, the deposition of separating layers DE 10 2009 048 658 A1 .
  • the electrically insulating separating layer can be applied to the respective amorphous film by continuous material bonding, for example using a sprayed-on adhesive or another adhesive, of the amorphous film with a film forming the separating layer.
  • the electrically insulating separating layer can be formed on the respective amorphous film, for example, by continuously applying, for example by means of an application roller or by spraying, an insulating material onto the amorphous film, which after its application hardens as quickly as possible to form the separating layer.
  • the separation layer can be formed on the respective amorphous film by treating a main side of the amorphous film as described above.
  • An electrically insulating separating layer can also be arranged or formed on each side of the respective amorphous film.
  • the respective one with the at least one separating layer The amorphous film provided can then be reeled into a film roll in order to be available for further processing and / or processing.
  • the arrangement or formation of at least one separating layer on each of the amorphous foils represents a variant of the above-mentioned first semifinished product for producing the package section of a soft magnetic component of an electrical machine.
  • the method comprises the further steps: continuous longitudinal division of the film composite at at least one point of a cross section of the film composite; continuous longitudinal division of at least one correspondingly produced further film composite at at least one point of a cross section of the further film composite, the film composite being longitudinally divided with respect to a cross-sectional width at a different point than the further film composite; and continuous production of an at least two-layer, band-shaped multicomponent composite by continuously materially connecting the longitudinally divided film composites to one another.
  • the strip-shaped multi-component composite is a second semi-finished product for producing the package section of a soft magnetic component of an electrical machine.
  • the multi-component composite is reeled into a composite roll in order to be available for later processing and / or processing.
  • a multi-component composite of any desired width can be produced by staggered arrangement of the composite sections produced by the respective longitudinal division of the respective film composite and material connection of the composite sections.
  • the film composite can be longitudinally divided, for example, at a single point of its cross-sectional area, while the further film composite can be longitudinally divided, for example, at two points of its cross-sectional area, which corresponds to the cross-sectional area of the first-mentioned film composite.
  • the multicomponent composite can be formed by an alternating arrangement of these two film composites, wherein the multicomponent composite can also be formed from more than two film composites.
  • the individual film composites can also have a different number of longitudinal divisions. For the formation of the multicomponent composite, it is essential that longitudinal divisions of adjacent film composites are offset from one another with respect to the longitudinal extension of the multicomponent composite are or are not arranged in alignment with one another in the direction of the thickness of the multi-component composite.
  • the continuous cohesive connection of the film composites to one another can take place by means of an adhesive or another adhesive which is applied continuously to at least one of the film composites by means of an application roller or by spraying.
  • the adhesive or the adhesive can be designed to be electrically insulating.
  • the width of the multi-component composite can, for example, be in a range from approximately 200 mm to approximately 1000 mm.
  • the thickness of the multi-component composite can, for example, be in a range from approximately 40 ⁇ m to approximately 2000 ⁇ m.
  • an at least two-layer, strip-shaped multicomponent composite is produced by continuously materially connecting the film composite to at least one correspondingly produced further film composite.
  • This strip-shaped multicomponent composite is a semifinished product alternative to the above-mentioned second semifinished product for producing the package section of a soft magnetic component of an electrical machine.
  • the multicomponent composite can also be formed from more than two film composites.
  • the multi-component composite can be reeled into a composite roll in order to be available for later processing and / or processing.
  • the cohesive connection of the film composites can take place by means of an adhesive or another adhesive which is applied continuously to at least one of the film composites by means of an application roller or by spraying.
  • the adhesive or the adhesive can be designed to be electrically insulating.
  • the width of the multi-component composite can, for example, be in a range from approximately 40 mm to approximately 250 mm.
  • the thickness of the multi-component composite can, for example, be in a range from approximately 40 ⁇ m to approximately 2000 ⁇ m.
  • At least one composite body is produced by separating composite sections of the multicomponent composite from the remaining multicomponent composite, stacking them and connecting them to one another in a materially bonded manner.
  • This allows semi-finished products to be used in the manufacture of the package section a soft magnetic component of an electrical machine in the form of monolithic composite bodies with a certain size and shape can be produced.
  • the thickness of such a composite body can, for example, be in a range from approximately 3 mm to approximately 400 mm.
  • the width of such a composite body can, for example, be in a range from approximately 30 mm to 1000 mm.
  • the length of such a composite body can, for example, be in a range from about 100 mm to 2500 mm.
  • the composite sections can be selected, stacked and cohesively connected to one another, for example, in such a way that the respective composite body formed therefrom has, for example, a rectangular, trapezoidal or otherwise formed cut surface. At least one groove or the like can also be formed on at least one side surface of the respectively formed composite body.
  • the composite sections can have different thicknesses, lengths and / or widths in order to produce a step-like bevel of the composite body formed therefrom.
  • the package section is produced by materially connecting composite bodies of the same or different width and / or length, a cross-sectional area of the package section being formed with a gradation through the use of composite bodies of different width or length at at least one corner area .
  • a packet section for example in the form of a coil-accommodating leg of the transformer core, can be given an approximately circular, elliptical or oval cross-sectional area, for which each corner area is designed with a corresponding gradation.
  • a package section designed as a yoke of the transformer core can, for example, have a rectangular cross-sectional area.
  • the composite bodies can be connected to one another via an adhesive or another adhesive.
  • the adhesive or the adhesive can be designed to be electrically insulating.
  • At least two package sections are produced accordingly and connected to one another in a materially and / or form-fitting manner.
  • One package section can be, for example, a yoke of the transformer core, while the other package section can be, for example, a leg for the arrangement of coils.
  • the soft magnetic component can also have more than two corresponding package sections and, for example, completely corresponding package sections be formed.
  • an E-shaped component can be formed which has a package section designed as a yoke and three package sections designed as legs.
  • Another package section of the transformer core is also designed as a yoke, which is connected to the free ends of the legs after the coils have been arranged on the legs.
  • At least one leg can be connected to the respective yoke with a butt joint, that is to say at an intersection angle of 90 °, and in a materially bonded manner.
  • at least one leg can also be connected to the yoke using a different angle of intersection, for example an angle of intersection of 45 °.
  • the connecting sections of the respective limb and of the respective yoke can be designed in such a way that sections of limb and yoke mutually overlap.
  • the overlapping sections can be materially connected to one another.
  • a connecting section of a leg can have so-called step-lap layering.
  • the individual legs of a transformer core can be designed in various ways and connected to the respective yoke.
  • at least one leg can be connected to at least one yoke in at least two different of the named ways.
  • At least one abutment surface of abutment surfaces of the packet sections to be connected to one another is at least partially physically and / or chemically treated before the packet sections are connected.
  • the abutting surface can be provided with a desired surface roughness, for example.
  • the treatment of the abutment surface can serve to produce plane parallelism between abutment surfaces to be connected to one another. Both abutment surfaces to be connected can also be treated accordingly.
  • the physical treatment can, for example, be mechanical, in particular machining, or thermal.
  • a semifinished product not according to the invention for the production of at least one package section of a soft magnetic component of an electrical machine has at least one strip-shaped film composite which has at least two strip-shaped, soft magnetic films with an amorphous and / or nanocrystalline microstructure an iron alloy, in particular an FeSiB alloy, which are materially connected to one another.
  • This semifinished product corresponds to the first semifinished product mentioned above with reference to the method. Therefore, the advantages and design variants mentioned above with reference to the first semifinished product can be correspondingly combined with the semifinished product according to the invention.
  • an electrically insulating separating layer can be arranged or formed on at least one side of each film.
  • an adhesive used to form the bond between the amorphous foils or another adhesive used for this purpose can be designed to be electrically insulating.
  • An electrically insulating separating layer can be arranged or formed on at least one side of the film composite.
  • a semifinished product according to the invention for the production of at least one package section of a soft magnetic component of an electrical machine has at least one strip-shaped multi-component composite which has at least two materially bonded composite layers which are each formed from a longitudinally divided film composite, one film composite having a cross-sectional width of the multi-component composite at a different point than the further film composite arranged adjacent to the first film composite, each film composite having at least two band-shaped, soft magnetic films with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular a FeSiB alloy, which are firmly bonded to one another .
  • This semifinished product corresponds to the second semifinished product mentioned above with reference to the method. Therefore, the advantages and design variants mentioned above with reference to the second semifinished product can be correspondingly combined with the semifinished product according to the invention.
  • a package section not according to the invention for a soft magnetic component of an electrical machine is formed by a stack of cohesively interconnected composite bodies, which are each formed from composite sections cut to length of a strip-shaped multi-component composite which has at least two cohesively interconnected composite layers, which are each formed from a longitudinally divided film composite , wherein the one film composite is longer with respect to a cross-sectional width of the respective composite body of a different cross-sectional location than the further film composite arranged adjacent to the first film composite, each film composite at least two band-shaped, soft magnetic Has foils with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy, which are materially connected to one another.
  • the package section can be produced using the method according to one of the above-mentioned configurations or a combination of at least two of these configurations with one another.
  • configurations of the above-mentioned method can correspond to configurations of the packet section.
  • a width and / or length of the composite bodies is the same over a height of the stack or decreases in a step-like manner in at least one end region of the stack given with respect to the height at least partially towards the free end of the end region.
  • a soft magnetic component of an electrical machine according to the invention has at least two package sections according to one of the aforementioned configurations or a combination of at least two of these configurations with one another, which are materially and / or positively connected to one another.
  • Fig. 1 shows a method for producing at least one package section of a soft magnetic component of an electrical machine.
  • At least two strip-shaped, soft magnetic foils each with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy, are continuously produced using a casting process.
  • the two amorphous foils can be produced separately in separate production processes or in a common production process in direct succession, in the latter case the two amorphous foils being separate sections of the same cast strand. After their production, the two amorphous foils can each be reeled into a foil roll.
  • a tape-like film composite is continuously produced by continuously integrally connecting the two amorphous films to one another, with an adhesive or other adhesive being continuously applied to at least one amorphous film for the integral joining of the amorphous films.
  • at least one electrically insulating separating layer can be applied continuously to each of the films, at least on one side or formed on each of the foils.
  • at least one electrically insulating separating layer can be arranged or formed on at least one side of the film composite.
  • the film composite can be reeled up after its production.
  • a first semifinished product is produced, which accordingly Fig. 2 (a) or 2 (b) can be formed.
  • the film composite produced in method step 200 is continuously divided lengthways at at least one point of a cross section of the film composite.
  • at least one further film composite produced in accordance with method step 200 is continuously longitudinally divided at at least one point of a cross section of the further film composite, the film composite being longitudinally divided at a different point with respect to a cross-sectional width than the further film composite.
  • method step 300 can be omitted.
  • an at least two-layer, strip-shaped multicomponent composite is continuously produced by continuous material connection of the film composites or non-longitudinally divided film composites with one another in process step 300.
  • the multi-component composite can be reeled after its production.
  • a second semifinished product is produced, which accordingly Fig. 3 (a) can be formed.
  • an at least two-layer, strip-shaped multicomponent composite can be continuously produced by continuous material connection of the film composite to at least one correspondingly produced further film composite.
  • a second semifinished product is produced, which accordingly Fig. 3 (b) can be formed.
  • method step 600 at least one composite body is produced by separating composite sections of the multicomponent composite from the remaining multicomponent composite, stacking them and connecting them to one another in a materially bonded manner.
  • a semifinished product is produced, which accordingly Fig. 4 (a), 4 (b) or 4 (c) can be formed.
  • the package section is produced by materially joining composite bodies of the same or different width and / or length, a cross-sectional area of the package section being formed with a gradation by using composite bodies of different width or length at at least one corner area.
  • package sections can be produced which correspond to those shown in FIGS Figs. 5 to 7 Embodiments shown can be formed.
  • at least two package sections can also be produced accordingly and connected to one another in a materially and / or form-fitting manner.
  • At least one abutment surface of the abutment surfaces of the packet sections to be connected to one another is at least partially treated physically and / or chemically before the packet sections are connected.
  • Fig. 2 (a) shows a schematic and perspective illustration of an exemplary embodiment for a semifinished product 1 for the production of at least one soft magnetic component (not shown) of an electrical machine (not shown).
  • the semi-finished product 1 has a strip-shaped film composite 2.
  • the film composite 2 has five band-shaped, soft magnetic films 3 with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy.
  • Amorphous foils 3 arranged adjacent to one another are connected to one another in a materially bonded manner via an adhesive 4.
  • An electrically insulating separating layer 5 can optionally be arranged or formed on at least one side of the film composite 2, which is shown in FIG Fig. 2 (a) is indicated by a dashed line.
  • Fig. 2 (b) shows a schematic and perspective illustration of a further exemplary embodiment for a semifinished product 6 for the production of at least one package section (not shown) of a soft magnetic component (not shown) of an electrical machine (not shown).
  • the semi-finished product 6 has a strip-shaped film composite 7.
  • the film composite 7 has five band-shaped, soft magnetic films 3 with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy.
  • Amorphous foils 3 arranged adjacent to one another are via a Adhesive 4 cohesively connected to one another.
  • An electrically insulating separating layer 8 is arranged or formed on one side of each amorphous film 3.
  • An electrically insulating separating layer 5 can optionally be correspondingly applied to the film composite 2 Fig. 2 (b) be arranged or formed in Fig. 2 (b) is indicated by a dashed line.
  • Fig. 3 (a) shows a schematic and perspective illustration of an exemplary embodiment for a semifinished product 9 according to the invention for the production of at least one package section (not shown) of a soft magnetic component (not shown) of an electrical machine (not shown).
  • the semi-finished product 9 has a strip-shaped multi-component composite 10.
  • the multi-component composite 10 has three composite layers 11 to 13 connected to one another in a materially bonded manner. Each composite layer 11 or 12 or 13 is formed from a longitudinally divided film composite 14 or 15 or 16.
  • the middle film composite 15 is longitudinally divided with respect to a cross-sectional width B of the multi-component composite 10 at a different point than the two further film composites 14 and 16 arranged adjacent to the film composite 15.
  • the film composite 15 is simply longitudinally divided only in a central area, while the two further film composites 14 and 16 are split lengthways in two.
  • the composite layers 11 and 13 or the film composites 14 and 16 are designed in the same way.
  • Each foil composite 14 or 15 or 16 has at least two band-shaped, soft magnetic foils (not shown) with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy, which are firmly bonded to one another.
  • the film composites 14 to 16 can be divided accordingly in front of their respective longitudinal division Fig. 2 (a) or 2 (b) be trained.
  • An electrical insulation (not shown), for example in the form of a separating layer (not shown), can be arranged or formed on at least one side of the semifinished product 9.
  • Fig. 3 (b) shows a schematic and perspective illustration of a further exemplary embodiment for a semifinished product 17 for the production of at least one package section (not shown) of a soft magnetic component (not shown) of an electrical machine (not shown).
  • the semifinished product 17 has a strip-shaped multi-component composite 18.
  • the multicomponent composite 18 has three composite layers 19 connected to one another in a materially bonded manner.
  • the composite layers 19 are each formed from a film composite 20.
  • the composite layers 19 are designed in the same way.
  • Each film composite 20 has at least two strip-shaped, soft magnetic films (not shown) with an amorphous and / or nanocrystalline microstructure made of an iron alloy, in particular an FeSiB alloy, which are materially connected to one another.
  • the film composites 20 can accordingly Fig. 2 (a) or 2 (b) be trained.
  • An electrical insulation (not shown), for example in the form of a separating layer (not shown), can be arranged or formed on at least one side of the semifinished product 17.
  • Fig. 4 (a) shows a schematic and perspective representation of an exemplary embodiment of a composite body 21 that can be produced using the method according to the invention.
  • the composite body 21 is produced by separating composite sections (not shown) of a multicomponent composite (not shown) from the rest of the multicomponent composite, stacking them and connecting them to one another in an integral manner.
  • the multi-component composite can accordingly Fig. 3 (a) or 3 (b) be trained.
  • the composite body 21 is cuboid.
  • An electrical insulation (not shown) for example in the form of a separating layer (not shown), can be arranged or formed on at least one side of the composite body 21.
  • Fig. 4 (b) shows a schematic representation of an exemplary embodiment of a composite body 22 that can be produced using the method according to the invention.
  • the composite body 22 is produced by separating, stacking and integrally connecting non-illustrated composite sections of a multicomponent composite (not shown) from the rest of the multicomponent composite.
  • the multi-component composite can accordingly Fig. 3 (a) or 3 (b) be trained.
  • the composite body 22 has a trapezoidal cut surface.
  • An electrical insulation (not shown) for example in the form of a separating layer (not shown), can be arranged or formed on at least one side of the composite body 22.
  • Fig. 4 (c) shows a schematic representation of an exemplary embodiment for a composite body 23 which can be produced using the method according to the invention.
  • the composite body 23 is produced by connecting sections (not shown) of a composite body (not shown) Multicomponent composite can be separated from the rest of the multicomponent composite, stacked and firmly connected to one another.
  • the multi-component composite can accordingly Fig. 3 (a) or 3 (b) be trained.
  • the composite body 23 has a trapezoidal cut surface with a recess 24 on one side.
  • An electrical insulation (not shown), for example in the form of a separating layer (not shown), can be arranged or formed on at least one side of the composite body 23.
  • Fig. 5 (a) shows a schematic representation of an embodiment for a soft magnetic component 25 in the form of a transformer core for a three-phase transformer, not shown.
  • the soft magnetic component 25 has three package sections 26 running parallel to one another in the form of legs, which are configured identically and each serve to accommodate a primary coil (not shown) and a secondary coil (not shown) of the same current phase. Furthermore, the soft magnetic component 25 has two package sections 27 in the form of yokes that can be connected to the package sections 26 at each end.
  • the package sections 26 are each corresponding Fig. 5 (c) formed and the package sections 27 are corresponding Fig. 5 (b) educated.
  • Each package section 26 or 27 is formed by a stack of composite bodies (not shown) that are connected to one another in a materially bonded manner. The composite bodies can, for example, accordingly Fig. 4 (a), 4 (b) or 4 (c) be trained.
  • Fig. 5 (b) shows a schematic and perspective illustration of an in Fig. 5 (a) shown package section 27 in the form of a yoke.
  • the package section 27 is cuboid. At least one edge of the package section 27 can be chamfered to save material.
  • Fig. 5 (c) shows a schematic and perspective illustration of an in Fig. 5 (a) shown package section 26 in the form of a leg.
  • a cross-sectional area of the package section 26 is formed with a gradation in each case through the use of composite bodies of different widths at all corner regions.
  • Fig. 6 (a) shows a schematic cross-sectional representation of an embodiment for a package section 28 in the form of a leg.
  • the package section 28 is made up of a stack of composite bodies that are firmly bonded to one another 29 formed.
  • a cross-sectional area of the package section 28 is formed by the use of composite bodies 29 of different widths in each of the corner regions with a gradation.
  • Fig. 6 (b) shows a schematic cross-sectional illustration of an exemplary embodiment for a package section 30 in the form of a yoke.
  • the package section 30 is formed by a stack of composite bodies 31 connected to one another in a materially bonded manner.
  • a cross-sectional area of the package section 30 is rectangular through the use of composite bodies 31 of the same width.
  • FIG. 11 shows a schematic illustration of a section of a further exemplary embodiment for a soft magnetic component 32 in the form of a transformer core, of which FIG Fig. 7 (a) only one section is shown.
  • the package section 33 is connected to the package section 34 via a butt joint (cutting angle 90 °).
  • abutment surface 35 or 36 of abutment surfaces 35 and 36 of the package sections 33 and 34 to be connected to one another may have been at least partially physically and / or chemically treated before the package sections 33 and 34 are connected.
  • FIG. 11 shows a schematic representation of a section of a further exemplary embodiment for a soft magnetic component 37 in the form of a transformer core, of which FIG Fig. 7 (b) only one section is shown.
  • the connection area between a package section 38 in the form of an outer leg and a package section 39 in the form of a yoke is shown.
  • the connecting sections (not shown in more detail) of the package sections 38 and 39 are designed in such a way that connecting sections overlap one another or engage in one another to produce a form fit.
  • the interlocking connecting sections are materially connected to one another.
  • FIG. 11 shows a schematic representation of a section of a further exemplary embodiment for a soft magnetic component in the form of a transformer core, of which FIG Fig. 7 (c) only one section is shown.
  • the connection area between a package section 41 is in the form of an outer one Leg and a package portion 42 shown in the form of a yoke.
  • the connecting sections of the package sections 41 and 42 are each formed by a step-lap layering of the components of the package sections 41 and 42, which are not shown, as a result of which a miter connection between the package sections 41 and 42 is realized.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Dispersion Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Soft Magnetic Materials (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
EP17209155.5A 2017-12-20 2017-12-20 Verfahren und halbzeug zum herstellen von wenigstens einem paketabschnitt eines weichmagnetischen bauteils Active EP3503139B1 (de)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PL17209155T PL3503139T3 (pl) 2017-12-20 2017-12-20 Sposób i półfabrykat do wytwarzania co najmniej jednego odcinka pakietu magnetycznie miękkiego elementu
ES17209155T ES2876373T3 (es) 2017-12-20 2017-12-20 Procedimiento y producto semiacabado para la fabricación de al menos una sección de paquete de un componente magnético suave
EP17209155.5A EP3503139B1 (de) 2017-12-20 2017-12-20 Verfahren und halbzeug zum herstellen von wenigstens einem paketabschnitt eines weichmagnetischen bauteils

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP17209155.5A EP3503139B1 (de) 2017-12-20 2017-12-20 Verfahren und halbzeug zum herstellen von wenigstens einem paketabschnitt eines weichmagnetischen bauteils

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EP3503139A1 EP3503139A1 (de) 2019-06-26
EP3503139B1 true EP3503139B1 (de) 2021-03-31

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JP2021114811A (ja) * 2020-01-16 2021-08-05 トヨタ自動車株式会社 積層コア

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0633501B2 (ja) * 1986-09-30 1994-05-02 新日本製鐵株式会社 非晶質合金材料の表面処理方法
EP2811816A1 (en) * 2012-02-03 2014-12-10 Amosense Co. Ltd. Magnetic field shielding sheet for digitizer, manufacturing method thereof, and portable terminal device using same

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Publication number Priority date Publication date Assignee Title
US6737951B1 (en) * 2002-11-01 2004-05-18 Metglas, Inc. Bulk amorphous metal inductive device
WO2008133026A1 (ja) * 2007-04-13 2008-11-06 Hitachi Metals, Ltd. アンテナ用磁心、アンテナ用磁心の製造方法、およびアンテナ
DE102009048658A1 (de) 2009-09-29 2011-03-31 Siemens Aktiengesellschaft Transformatorkern oder Transformatorblech mit einer amorphen und/oder nanokristallinen Gefügestruktur und Verfahren zu dessen Herstellung
WO2012157053A1 (ja) * 2011-05-16 2012-11-22 株式会社日立製作所 リアクトル装置及びそれを用いた電力変換器
US9824818B2 (en) * 2011-10-19 2017-11-21 Keith D. Earhart Method of manufacturing wound transformer core
JP5676414B2 (ja) * 2011-11-01 2015-02-25 株式会社日立産機システム アモルファス鉄心変圧器

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0633501B2 (ja) * 1986-09-30 1994-05-02 新日本製鐵株式会社 非晶質合金材料の表面処理方法
EP2811816A1 (en) * 2012-02-03 2014-12-10 Amosense Co. Ltd. Magnetic field shielding sheet for digitizer, manufacturing method thereof, and portable terminal device using same

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PL3503139T3 (pl) 2021-10-18
EP3503139A1 (de) 2019-06-26

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