EP3588518B1 - Unité de noyau magnétique, transformateur de courant et leur procédé de fabrication - Google Patents

Unité de noyau magnétique, transformateur de courant et leur procédé de fabrication Download PDF

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EP3588518B1
EP3588518B1 EP18757370.4A EP18757370A EP3588518B1 EP 3588518 B1 EP3588518 B1 EP 3588518B1 EP 18757370 A EP18757370 A EP 18757370A EP 3588518 B1 EP3588518 B1 EP 3588518B1
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Prior art keywords
magnetic core
unit
core
magnetic
temperature
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German (de)
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EP3588518A1 (fr
EP3588518A4 (fr
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Kazuhiro Hagiwara
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Proterial Ltd
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Hitachi Metals Ltd
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    • 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
    • H01F1/15308—Amorphous metallic alloys, e.g. glassy metals based on Fe/Ni
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D6/00—Heat treatment of ferrous alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C22C45/02—Amorphous alloys with iron as the major constituent
    • 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
    • H01F27/25—Magnetic cores made from strips or ribbons
    • 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
    • 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

Definitions

  • the present disclosure relates to a magnetic core unit which includes a wound magnetic core formed by winding up a nanocrystalline alloy ribbon and a case for storing the wound magnetic core, a current transformer, and a manufacturing method thereof.
  • Soft magnetic alloy ribbons of an amorphous alloy, a nanocrystalline alloy, or the like, which are produced by a single-roll method have excellent soft magnetic characteristics and are therefore used for various magnetic parts.
  • the nanocrystalline alloy exhibits such excellent soft magnetic characteristics that it has a higher saturation magnetic flux density than Permalloy and Co-based amorphous alloys and has a higher magnetic permeability than Fe-based amorphous alloys.
  • the nanocrystalline alloy has been used in magnetic cores of common mode choke coils, high frequency transformers, pulse transformers, current transformers, etc.
  • the magnetic characteristics of the nanocrystalline alloy magnetic core can be greatly changed by a temperature profile in a heat treatment or by applying a magnetic field in a specific direction in a heat treatment.
  • Patent Document No. 1 discloses, for example, carrying out a heat treatment in a magnetic field through three heating steps. Specifically, Patent Document No. 1 discloses that a heat treatment for nanocrystallization is carried out, and thereafter, a heat treatment is carried out at a temperature lower than the temperature of the heat treatment for nanocrystallization in the presence of a magnetic field applied in a longitudinal direction (direction of magnetic path), and thereafter, a heat treatment is carried out in the presence of a magnetic field applied in a transverse direction (direction perpendicular to magnetic path).
  • Patent Document No. 2 and Patent Document No. 3 disclose that a first heat treatment for nanocrystallization is carried out in the absence of a magnetic field, and thereafter, a second heat treatment is carried out at a temperature lower than the temperature of the heat treatment for nanocrystallization in the presence of a magnetic field applied in a direction perpendicular to the magnetic path.
  • the wound magnetic core of the nanocrystalline alloy is likely to have chips, and techniques for solving this problem are important. If a coil is directly wound around the wound magnetic core, chips are formed at the edge of the magnetic core because the wound magnetic core of the nanocrystalline alloy is brittle as compared with a magnetic core formed of an amorphous ribbon. Alloy dust separated from the magnetic core can enter electric circuits of the apparatus and cause unintended electrical conduction or cut circuit wires. A traditional solution for suppressing occurrence of this alloy dust is storing a wound magnetic core in a non-magnetic case which is made of a resin or the like and winding a coil outside the case. Patent Document No.
  • m [kg] is the mass of the wound magnetic core
  • E [N/m 2 ] is the Young's modulus of an adhesive agent after being cured
  • d [m] is the total thickness of the adhesive agent provided in a gap between the end face of the magnetic core and the case
  • a [m 2 ] is the total adhesion area of the adhesive agent between the end face of the magnetic core and the case.
  • Patent Document No. 4 considers anti-noise techniques for a case where an amorphous alloy whose magnetostriction exceeds 10 ppm is used.
  • Patent Document No. 5 discloses a magnet core that is wound from a magnetically soft band.
  • Patent Document No. 6 relates to a pulse transformer magnetic core comprising a magnetic core main body of a soft magnetic allow ribbon, the soft magnetic alloy ribbon may be coiled or be stacked rings or E-Shape and I-shape pieces which are made from the soft magnetic alloy ribbon by a punching process.
  • Patent Document No. 7 is directed to a method to prevent deterioration in magnetic characteristics wherein gel-like resin is used as a fixing means with which a wound magnetic core is fixed to a case.
  • Patent Document No. 8 discloses a wound core included in a core case with an adhesive support being approximately 40% or less portion of the total volume of the void between core an core case.
  • the present disclosure provides a magnetic core unit whose magnetic permeability exhibits a small change with respect to the temperature through a relatively simple heat treatment, a current transformer, and a manufacturing method thereof.
  • a magnetic core unit of the present disclosure is described in claim 1.
  • a change rate ⁇ between the magnetic permeability ⁇ unit (25) before the magnetic core unit is maintained at 100°C for 100 hours and the magnetic permeability ⁇ unit (25) after the magnetic core unit is maintained at 100°C for 100 hours is within ⁇ 6%.
  • the magnetic permeability ⁇ unit (25) is not more than 700000.
  • the adhesive agent has a Shore A hardness of not less than 10 and less than 50.
  • a current transformer of the present disclosure as defined in claim 5, includes the above-described magnetic core unit.
  • a method for manufacturing a magnetic core unit the present disclosure is described in claim 6.
  • a highest temperature of the second heat treatment is equal to or higher than 225°C and equal to or lower than 270°C.
  • a temperature rise rate at the crystallization initiating temperature is not more than 5°C/min.
  • the adhesive agent has a Shore A hardness of not less than 10 and less than 50.
  • a method for manufacturing a current transformer of the present invention as defined in claim 10, includes:
  • a magnetic core unit whose magnetic permeability ⁇ exhibits a small change with respect to the temperature of a wound magnetic core even while the wound magnetic core is adhered to a case, a current transformer, and a manufacturing method thereof are realized.
  • the magnetic permeability and the squareness ratio Br/Bs of the nanocrystalline alloy ribbon can be adjusted by a heat treatment in a magnetic field.
  • the nanocrystalline alloy ribbon sometimes need to have such a temperature characteristic that the variation of the magnetic permeability of the core is small within a use temperature range in order to comply with the temperature variation of the use environment.
  • An example of a magnetic part which particularly need to have a temperature characteristic is a current transformer (CT).
  • the current transformer is a current transforming device for use in measurement and is used in, for example, current meters and earth leakage circuit breakers.
  • a wound magnetic core used in the current transformer is required to have a magnetic permeability whose change with respect to the temperature is small, such that a measurement error in the current value is small in any environment ranging from -25°C to 100°C.
  • the heat treatment method disclosed in Patent Document No. 1 which is carried out in a magnetic field through three steps (the method of heat treatment in magnetic field, consisting of three steps: a heat treatment for nanocrystallization is carried out in the absence of a magnetic field; thereafter, a heat treatment is carried out at a temperature lower than the temperature of the heat treatment for nanocrystallization in the presence of a magnetic field applied in a longitudinal direction (direction of magnetic path); and thereafter, a heat treatment is carried out in the presence of a magnetic field applied in a transverse direction (direction perpendicular to magnetic path), hereinafter referred to as "three-step heat treatment”) has such advantages that the magnetic permeability ⁇ (25) and the squareness ratio Br/Bs of a wound magnetic core formed of a resultant nanocrystalline alloy can be easily adjusted within the aforementioned value ranges and the wound magnetic core has a stable temperature characteristic although, disadvantageously, the manufacturing cost is high due to a large number of heat treatment step.
  • the heat treatment method such as disclosed in Patent Document No. 2 and Patent Document No. 3, which is carried out in a magnetic field through two steps (the method of heat treatment in magnetic field, consisting of two steps: a first heat treatment for nanocrystallization is carried out in the absence of a magnetic field; and thereafter, a second heat treatment is carried out at a temperature lower than the temperature of the heat treatment for nanocrystallization in the presence of a magnetic field applied in a transverse direction (a direction perpendicular to the magnetic path), hereinafter referred to as "two-step heat treatment”) has such a merit that high magnetic permeability and stable temperature characteristic which are approximately at the same level as those of Patent Document No. 1 can be realized at a low cost.
  • Patent Documents Nos. 2 and 3 do not have such a disclosure that the wound magnetic core before being adhered to the case and the magnetic core unit adhered to the case have varying temperature characteristics.
  • the highest temperature of the first heat treatment is 610°C, 620°C or 540°C.
  • the temperature of the nanocrystallization heat treatment is 520°C or 550°C. None of Patent Document No. 2 and Patent Document No. 3 discloses the relationship between the highest temperature of the first heat treatment and the temperature characteristic.
  • the saturated magnetostriction of a nanocrystalline alloy ribbon produced by the two-step heat treatment is relatively large, e.g., greater than 1 ppm, and when a wound magnetic core formed of this nanocrystalline alloy ribbon is adhered to a case using an adhesive agent, whereby a magnetic core unit is formed, the temperature characteristic of the magnetic core unit deteriorates, the present inventor studied a magnetic core unit which has improved temperature characteristic after being adhered to the case although the saturated magnetostriction of the nanocrystalline alloy ribbon is greater than 1 ppm, and a manufacturing method thereof.
  • the present inventor found that, in the temperature profile of the two-step heat treatment, the temperature characteristic of the wound magnetic core before being adhered to the case is maintained within a predetermined range, whereby the magnetic core unit of the present disclosure is realized. Further, the present inventor found that, as a specific manufacturing method, by setting the temperature in the first heat treatment within a predetermined range, a wound magnetic core which has a temperature characteristic within the above-described certain range is realized.
  • FIG. 15(a) is an exploded perspective view of one embodiment of a magnetic core unit of the present disclosure.
  • FIG. 15(b) shows a cross section vertical to the circumferential direction of the magnetic core unit.
  • the magnetic core unit 11 includes a wound magnetic core 13, a case 15, and an adhesive agent 16.
  • the case 15 includes a body 14 and a lid 12.
  • the body 14 of the case 15 has a space 14a corresponding to the external shape of the wound magnetic core 13.
  • the wound magnetic core 13 has a ring shape, and accordingly, the space 14a also has a ring shape.
  • 14b indicates the bottom surface of the space 14a of the body 14, and 12a indicates the ceiling surface of the lid 12.
  • the wound magnetic core 13 includes a wound nanocrystalline alloy ribbon.
  • the nanocrystalline alloy ribbon is wound in the circumferential direction and layered (or stacked).
  • the layered (or stacked) surfaces 13a, 13b are the top surface and the bottom surface.
  • the wound magnetic core 13 is stored in the space 14a of the body 14 of the case 15.
  • the lid 12 is provided over the opening of the space 14a of the body 14 so as to close the space 14a.
  • the nanocrystalline alloy ribbon has saturated magnetostriction which is greater than 1 ppm.
  • the magnetic permeability ⁇ unit (25) is not less than 400000 and the following formulae, Formula 1 and Formula 2, are satisfied: ⁇ 0.28 ⁇ ⁇ unit 100 ⁇ ⁇ unit 25 / ⁇ unit 25 ⁇ 0.1 ⁇ 0.28 ⁇ ⁇ unit ⁇ 25 ⁇ ⁇ unit 25 / ⁇ unit 25 ⁇ 0
  • Formula 1 shown above represents that the change rate of the magnetic permeability ⁇ unit (100) at 100°C of the magnetic core unit 11 from the magnetic permeability ⁇ unit (25) at 25°C is in the range from -28% to +10%.
  • Formula 2 shown above represents that the magnetic permeability ⁇ unit (-25) at -25°C of the magnetic core unit 11 is not greater than magnetic permeability ⁇ unit (25) at 25°C but is in the range of not less than -28%.
  • magnetic permeability ⁇ unit (T) satisfies the following formulae, Formula 1' and Formula 2'. ⁇ 0.20 ⁇ ⁇ unit 100 ⁇ ⁇ unit 25 / ⁇ unit 25 ⁇ 0 ⁇ 0.20 ⁇ ⁇ unit ⁇ 25 ⁇ ⁇ unit 25 / ⁇ unit 25 ⁇ 0
  • the change rate ⁇ between the magnetic permeability ⁇ unit (25) before the magnetic core unit 11 is maintained at 100°C for 100 hours and the magnetic permeability ⁇ unit (25) after the magnetic core unit 11 is maintained at 100°C for 100 hours is preferably within ⁇ 6%.
  • the magnetic core unit 11 can have excellent heat resistance. More preferably, the change rate ⁇ is within ⁇ 5%.
  • the magnetic permeability ⁇ unit (25) is preferably not more than 700000.
  • the nanocrystalline alloy ribbon is preferably made of an alloy which has a composition represented by Formula: (Fe 1-a M a ) 100-x-y-z- ⁇ - ⁇ - ⁇ Cu x Si y B z M' ⁇ M" ⁇ X ⁇ (atomic %) (M is Co and/or Ni, M' is at least one element selected from the group consisting of Nb, Mo, Ta, Ti, Zr, Hf, V, Cr, Mn and W, M" is at least one element selected from the group consisting of Al, platinum group elements, Sc, rare-earth elements, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, ⁇ , ⁇ and ⁇ satisfy 0 ⁇ a ⁇ 0.5, 0.1 ⁇ x ⁇ 3, 0 ⁇ y ⁇ 30, 0 ⁇ z ⁇ 25, 5 ⁇ y+z ⁇ 30, 0 ⁇ 20, 0 ⁇ 20 and 0 ⁇ 20
  • the adhesive agent 16 is provided between the bottom surface 14b of the space of the body 14 of the case 15 and the layered surface 13b of the wound magnetic core 13 and partially adheres the wound magnetic core 13 to the bottom surface 14b.
  • the adhesive agent 16 does not cover the entirety of the layered surface 13b. Since the layered surface 13b is partially adhered to the bottom surface 14b of the case 15 by the adhesive agent 16, expansion and shrinkage of the nanocrystalline alloy ribbon at the layered surface is allowed even if the case or the adhesive agent expands or shrinks, and occurrence of stress in the nanocrystalline alloy ribbon is suppressed. Therefore, variation of the temperature characteristic due to the stress is suppressed.
  • the site at which the wound magnetic core 13 is partially adhered to the case can be on the ceiling surface 12a of the lid 12.
  • the layered surface 13b of the wound magnetic core 13 is adhered to the case 15 by the adhesive agent 16 in a range of not less than 30% and not more than 50% with respect to the area of the layered surface 13b of the wound magnetic core 13.
  • the adhesive agent 16 preferably has a Shore A hardness of not less than 10 and less than 50. When the Shore A hardness is in this range, the adhesive agent 16 is relatively soft. Therefore, expansion and shrinkage of the nanocrystalline alloy ribbon due to the magnetostriction is allowed, and stress due to the magnetostriction can be reduced.
  • Such a magnetic core unit can be manufactured, for example, by the following method.
  • a magnetic core element formed by winding up an amorphous alloy ribbon having a composition represented by Formula: (Fe 1-a M a ) 100-x-y-z- ⁇ - ⁇ - ⁇ Cu x Si y B z M' ⁇ M" ⁇ X ⁇ (atomic %)
  • M is Co and/or Ni
  • M' is at least one element selected from the group consisting of Nb, Mo, Ta, Ti, Zr, Hf, V, Cr, Mn and W
  • M" is at least one element selected from the group consisting of Al, platinum group elements, Sc, rare-earth elements, Zn, Sn and Re
  • X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As
  • a, x, y, z, ⁇ , ⁇ and ⁇ satisfy 0 ⁇ a ⁇ 0.5, 0.1 ⁇ x ⁇ 3, 0 ⁇ y ⁇ 30, 0 ⁇ z ⁇ 25, 5 ⁇ y+z ⁇ 30, 0
  • the first heat treatment and the second heat treatment are performed on the magnetic core element.
  • the first heat treatment includes heating the magnetic core element at a temperature equal to or higher than the crystallization initiating temperature in the absence of a magnetic field.
  • the second heat treatment includes heating the magnetic core element at a temperature lower than the crystallization initiating temperature. In the second heat treatment, a magnetic field is applied in a direction perpendicular to the magnetic path.
  • a wound magnetic core 13 is produced whose saturated magnetostriction is greater than 1 ppm, whose magnetic permeability ⁇ core (25) is not less than 400000, and which satisfies the following formulae, Formula 3 and Formula 4: 0 ⁇ ⁇ core ⁇ 25 ⁇ ⁇ core 25 / ⁇ core 25 ⁇ 0.25 ⁇ ⁇ core 100 ⁇ ⁇ core 25 / ⁇ core 25 ⁇ 0
  • a nanocrystalline alloy ribbon Due to the first heat treatment and the second heat treatment, a nanocrystalline alloy ribbon can be realized whose saturated magnetostriction is greater than 1 ppm.
  • a magnetic core unit 11 which includes a wound magnetic core of excellent temperature characteristic can be realized even if the magnetic core unit 11 is produced by adhering the wound magnetic core 13 to the case 15.
  • the highest temperature of the first heat treatment is preferably equal to or higher than 520°C and equal to or lower than 550°C. More preferably, the highest temperature of the first heat treatment is equal to or higher than 530°C and lower than 545°C.
  • a magnetic core unit 11 whose magnetic permeability ⁇ core (T) satisfies Formula 4' is preferably realized. ⁇ 0.20 ⁇ ⁇ core 100 ⁇ ⁇ core 25 / ⁇ core 25 ⁇ ⁇ 0.05
  • the highest temperature of the second heat treatment is preferably equal to or higher than 225°C and equal to or lower than 270°C.
  • the temperature rise rate at the crystallization initiating temperature is preferably not more than 5°C/min.
  • the adhesive agent 16 is partially provided between the case 15 that has the space 14a corresponding to the external shape of the wound magnetic core 13 and the layered surface 13b or the layered surface 13a of the wound magnetic core 13, whereby the wound magnetic core 13 is adhered to the case 15. Thereby, the magnetic core unit is completed.
  • the site in the case at which the adhesive agent 16 is to be provided can be on the bottom surface 14b of the space 14a or on the ceiling surface 12a of the lid 12.
  • an example of an amorphous alloy which is capable of nanocrystallization is an alloy which has a composition represented by Formula: (Fe 1-a M a ) 100-x-y-z- ⁇ - ⁇ - ⁇ Cu x Si y B z M' ⁇ M" ⁇ X ⁇ (atomic %) (M is Co and/or Ni, M' is at least one element selected from the group consisting of Nb, Mo, Ta, Ti, Zr, Hf, V, Cr, Mn and W, M" is at least one element selected from the group consisting of Al, platinum group elements, Sc, rare-earth elements, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, ⁇ , ⁇ and ⁇ satisfy 0 ⁇ a ⁇ 0.5, 0.1 ⁇ x ⁇ 3, 0 ⁇ y ⁇ 30, 0 ⁇ z ⁇ 25, 5 ⁇ y+z ⁇ 30, 0
  • An alloy which has the above-described composition is melted to a temperature equal to or higher than the melting point and then quenched and solidified by a single-roll method or the like, resulting in a lengthy amorphous alloy ribbon.
  • the amorphous alloy ribbon is wound up into a magnetic core element which has a ring shape.
  • a small gap or any other substance may be present between layers of the amorphous alloy ribbon.
  • the volume occupancy of the amorphous alloy ribbon in the magnetic core element is, for example, about 70% to 90%.
  • the first heat treatment is performed on the amorphous alloy ribbon such that the amorphous alloy ribbon is heated to a temperature equal to or higher than the crystallization initiating temperature, whereby nanocrystallization of the ribbon is carried out.
  • the highest temperature of the first heat treatment is equal to or higher than 520°C and equal to or lower than 550°C. If it is equal to or higher than 520°C, the magnetic permeability ⁇ unit (100) at 100°C of the magnetic core unit is prevented from being greater by more than 10% than the magnetic permeability ⁇ unit (25) at room temperature and is prevented from being smaller than -28%.
  • the magnetic permeability ⁇ unit (-25) at -25°C of the magnetic core unit is prevented from being greater than the magnetic permeability ⁇ unit (25) at room temperature and is prevented from being smaller than -28%, although the saturated magnetostriction is greater than 1 ppm.
  • the magnetic permeability ⁇ core (-25) at -25°C of the wound magnetic core before being adhered to the case can be controlled so as to be greater than the magnetic permeability ⁇ core (25) at room temperature. If the highest temperature of the first heat treatment is equal to or lower than 550°C, the magnetic permeability ⁇ core (100) at 100°C of the wound magnetic core is prevented from being greater than the magnetic permeability ⁇ core (25) at room temperature and is prevented from being smaller than -25%, although the saturated magnetostriction is greater than 1 ppm.
  • the crystallization initiating temperature is defined as a temperature at which an exothermic reaction by initiation of nanocrystallization where the measurement condition of Differential Scanning Calorimetry (DSC) is the temperature rise rate of 10°C/min is detected.
  • DSC Differential Scanning Calorimetry
  • the highest temperature of the first heat treatment is preferably equal to or higher than 530°C and lower than 545°C.
  • a wound magnetic core is realized whose magnetic permeability ⁇ core (T) satisfies Formula 4': ⁇ 0.20 ⁇ ⁇ core 100 ⁇ ⁇ core 25 / ⁇ core 25 ⁇ ⁇ 0.05 .
  • a magnetic core unit formed by adhering this wound magnetic core to the case using a resin has magnetic permeability ⁇ unit (T) which satisfies Formula 1' and Formula 2' shown below, i.e., has further improved temperature characteristic.
  • T magnetic permeability
  • a magnetic core unit for a current transformer is, in some cases, required to have such a characteristic that the change rate of magnetic permeability ⁇ unit (25) after being maintained at 100°C for 100 hours (hereinafter, also referred to as "high temperature temporal change rate ⁇ " or simply “ ⁇ ") is small.
  • the high temperature temporal change rate ⁇ is likely to decrease as the highest temperature of the first heat treatment increases.
  • the highest temperature of the first heat treatment is preferably equal to or higher than 530°C.
  • the highest temperature of the first heat treatment is preferably equal to or higher than 530°C and lower than 545°C.
  • the temperature does not necessarily need to be maintained at the highest temperature.
  • the temperature is preferably maintained at the highest temperature for a duration in the range of not less than 5 minutes and not more than 24 hours. If the maintenance duration at the highest temperature is not less than 5 minutes, the entirety of the alloy that forms the core is likely to have a uniform temperature and is therefore likely to have uniform magnetic characteristics. On the other hand, if the maintenance duration at the highest temperature is longer than 24 hours, the productivity deteriorates, and furthermore, the magnetic characteristics are likely to deteriorate due to excessively growth of crystal grains or production of crystal grains in a nonuniform form.
  • the temperature rise rate at the crystallization initiating temperature is preferably moderate. Stable nanocrystallization can be realized.
  • the upper limit of the temperature rise rate is preferably 5°C/min.
  • the coercivity Hc can be decreased, and the value of ( ⁇ core (100) - ⁇ core (25))/ ⁇ core (25) of the wound magnetic core can be easily set in the range of - 0.25 ⁇ ( ⁇ core (100) - ⁇ core (25)) / ⁇ core (25) ⁇ 0 .
  • the temperature rise rate is preferably not more than 3°C/min, more preferably not more than 2°C/min, still more preferably not more than 1.5°C, still more preferably not more than 1.4°C, and still more preferably not more than 1.2°C.
  • the lower limit of the temperature rise rate is not particularly limited.
  • the temperature rise rate is not less than 0.2°C/min, stable nanocrystallization can be realized. Further, the duration of the first heat treatment can be reduced. When the temperature rise rate is not less than 0.375°C/min, the coercivity Hc of the wound magnetic core can be decreased, and the duration of the first heat treatment can be further reduced. Details will be described later with examples.
  • the saturated magnetostriction of the nanocrystallized alloy ribbon is greater than 1 ppm but can be smaller than that of an amorphous alloy ribbon, and therefore, a magnetic core unit of excellent temperature characteristic can be realized.
  • the temperature can be relatively rapidly increased at a temperature rise rate of, for example, 3-5°C/min.
  • Cooling down from the highest reached temperature is preferably carried out at a cooling rate of 1-5°C/min.
  • the alloy ribbon may be cooled to room temperature or may be cooled to the temperature of the second heat treatment, which will be described later, before being subjected to the second heat treatment at that temperature.
  • At least 50 volume%, or 80 volume%, of the nanocrystallized alloy ribbon is occupied by minute crystal grains whose average grain diameter measured at the maximum dimension is not more than 100 nm.
  • the other part of the alloy than the minute crystal grains is mainly amorphous.
  • the proportion of the minute crystal grains may be substantially 100 volume%.
  • the second heat treatment is performed by heating at a temperature lower than the crystallization initiating temperature.
  • the step of this second heat treatment includes the step of applying a magnetic field in a direction perpendicular to the magnetic path. Thereby, the magnetic core element is changed into a wound magnetic core.
  • the direction of an applied magnetic field is perpendicular to the direction of the magnetic path.
  • the magnetic field can be applied in the vertical direction of the magnetic core.
  • Application of the magnetic field may be realized by either of a DC magnetic field, an AC magnetic field or a pulsed magnetic field.
  • the second heat treatment is performed separately from the first heat treatment, and only the step of the second heat treatment includes the step of applying a magnetic field, so that a soft magnetic characteristic of high linearity can be achieved.
  • This heat treatment in a magnetic field contributes to decreasing the residual magnetic flux density Br although the magnetic permeability decreases, and the squareness ratio Br/Bm can be decreased to the range of, for example, 0.50 ⁇ Br/Bm ⁇ 0.85, resulting in a magnetic core in which magnetic bias is unlikely to occur.
  • These magnetic characteristics are suitable to current transformers.
  • the highest temperature of the second heat treatment is preferably equal to or higher than 225°C and equal to or lower than 270°C.
  • the magnetic permeability ⁇ unit (25) of the magnetic core unit can easily be set in the range of not less than 400000 and not more than 700000.
  • a more preferred lower limit of the highest temperature of the second heat treatment is 230°C.
  • a more preferred upper limit of the highest temperature of the second heat treatment is 265°C.
  • the temperature does not necessarily need to be maintained at the highest temperature.
  • the second heat treatment can be performed without maintenance duration.
  • the maintenance duration is preferably set in the range of not less than 5 minutes and not more than 24 hours. If the maintenance duration is not less than 5 minutes, the entirety of the alloy that forms the core is likely to have a uniform temperature and is therefore likely to have uniform magnetic characteristics. On the other hand, if the maintenance duration is longer than 24 hours, the productivity deteriorates, and furthermore, the magnetic characteristics are likely to deteriorate due to excessively growth of crystal grains or production of crystal grains in a nonuniform form.
  • the magnetic field can be applied while the temperature is maintained at the highest temperature.
  • the temperature can be increased to a predetermined temperature in the absence of a magnetic field, and thereafter, the magnetic field can be applied while the temperature is decreased. Still alternatively, the temperature can be increased to a predetermined temperature and maintained for a predetermined time period in the absence of a magnetic field, and thereafter, the magnetic field can be applied while the temperature is decreased.
  • the temperature can be decreased to the maintained temperature of the second heat treatment so that the second heat treatment can be performed without intermission.
  • the magnetic field applied in the second heat treatment is preferably applied at a magnetic field intensity of not less than 50 kA/m. If the applied magnetic field is excessively weak, provision of induced magnetic anisotropy under actual operative conditions is difficult. A more preferred range is not less than 60 kA/m. A still more preferred range is not less than 100 kA/m.
  • the magnetic field intensity is preferably not more than 400 kA/m because the induced magnetic anisotropy is not further provided even if the magnetic field intensity is more than 400 kA/m.
  • a wound magnetic core or magnetic core unit has a squareness ratio Br/Bm in the range of 0.50 ⁇ Br/Bm ⁇ 0.85
  • a magnetic field is applied at a magnetic field intensity of not less than 50 kA/m in a temperature range of at least equal to or higher than 225°C and equal to or lower than 270°C.
  • the duration for which the magnetic field is applied is preferably not less than 10 minutes and not more than 10 hours.
  • the temperature decrease rate and the magnetic field application duration are preferably adjusted such that the magnetic field is applied at a magnetic field intensity of not less than 50 kA/m in a temperature range of equal to or higher than 225°C and equal to or lower than 270°C.
  • the duration for which the magnetic field is applied is preferably not less than 10 minutes and not more than 10 hours likewise as in the above-described example.
  • the first heat treatment and the second heat treatment are preferably performed in a non-reactive atmosphere gas.
  • a nitrogen gas sufficient magnetic permeability is achieved, and the nitrogen gas can be substantially used as a non-reactive gas.
  • an inert gas can also be used.
  • the first heat treatment and the second heat treatment may be carried out in vacuum. Specifically, it is preferred that the first heat treatment and the second heat treatment are performed in an atmosphere whose oxygen concentration is not more than 10 ppm because the coercivity can be further reduced.
  • the case is used for the purpose of protecting the wound magnetic core and ensuring insulation. So long as such purposes are achieved, the material of the case is not particularly limited.
  • resins such as polyamide (PA), typically PA6 and PA66, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), etc., can be used.
  • a nanocrystalline alloy ribbon is cut out from the wound magnetic core or magnetic core unit so as to have a length of 5 cm in the magnetic path direction.
  • a strain gauge is adhered to the resultant nanocrystalline alloy ribbon via an adhesive agent. This nanocrystalline alloy ribbon with the adhered strain gauge is inserted into the inside diameter side of a solenoid coil, and the magnetostriction is measured while a sufficiently saturated magnetic field is applied.
  • the strain gauge used was a strain gauge manufactured by KYOWA ELECTRONIC INSTRUMENTS CO., LTD. (Product No.: KFN-2-350-C9-11).
  • the adhesive agent used was a cement adhesive agent manufactured by KYOWA ELECTRONIC INSTRUMENTS CO., LTD. (Product No.: CC-33A).
  • the device used for measuring the magnetostriction was a static strain measurement device manufactured by KYOWA ELECTRONIC INSTRUMENTS CO., LTD. (Product No.: SMD-10A).
  • the magnetic field applied in the measurement was 15.6 kA/m.
  • the magnetic permeability of a single wound magnetic core measured under the above-described conditions is represented as “magnetic permeability ⁇ core (T)” or simply “ ⁇ core (T)".
  • the magnetic permeability of a wound magnetic core which was measured while the wound magnetic core is adhered to the case is represented as “magnetic permeability ⁇ unit (T) or simply ⁇ unit ((T)”.
  • FIG. 16 is a diagram for illustrating the configuration of a measurement system used in measuring the magnetic permeability ⁇ (T) of a wound magnetic core or magnetic core unit for use in a current transformer or the like.
  • the primary side conductor 18 of an object of measurement is coupled with a function generator 54 which can generate an AC voltage signal having an arbitrary frequency and waveform, via a digital multimeter (DMM) 52 which can measure a DC voltage, direct current, AC voltage, and electrical resistance over wide ranges and a resistor R.
  • DDMM digital multimeter
  • the secondary side conductor 17 of the current transformer is coupled with another digital multimeter (DMM) 56 which is different from the digital multimeter 52 on the primary side conductor 18 side.
  • DDMM digital multimeter
  • the resistance value was set to 47 ohm, and digital multimeter 34401A manufactured by Agilent Technologies was used as the digital multimeters 52 and 56.
  • the function generator 54 multifunction generator WF1973 manufactured by NF CORPORATION was used, and an AC voltage signal was generated by the multifunction generator.
  • an adhesive agent is applied to only one of the layered surfaces (surfaces perpendicular to the roll axis) of the wound magnetic core.
  • the adhesive agent which can be suitably used include resin adhesive agents, thermosetting adhesive agents, silicone adhesive agents, instantaneous adhesive agents, and varnish materials.
  • the adhesive agent may be applied to the entirety of the layered surface.
  • the adhesion area between the case and the wound magnetic core is large, the temperature characteristic of the magnetic core unit after being adhered is likely to deteriorate due to the effects of magnetostriction.
  • the wound magnetic core is adhered to the case by an adhesive agent in a range of not less than 30% and not more than 50% with respect to the area of the layered surface (only one of the layered surfaces) of the wound magnetic core.
  • the ratio of the area of the adhesive agent to the area of this layered surface is referred to as "the area ratio of the adhesive agent" or simply "the area ratio”.
  • the area ratio of the adhesive agent is not less than 30%, the adhesion strength between the wound magnetic core and the case can be sufficiently secured, and separation of the wound magnetic core and the case can be suppressed.
  • the area ratio is not more than 50%, as will be described later, the temperature characteristic of the magnetic permeability ⁇ unit of the wound magnetic core after being adhered to the case can be improved. Further, a magnetic core unit whose high temperature temporal change rate ⁇ is not more than ⁇ 6% can be easily realized.
  • the adhesive agent preferably has a Shore A hardness of not less than 10 and less than 50.
  • the change of the magnetic permeability between before and after the wound magnetic core is adhered to the case can be reduced.
  • the aforementioned voltage value Vo (voltage value Vo in FIG. 16 ) is likely to greatly change between before and after the wound magnetic core is adhered to the case. Since the magnetic permeability ⁇ r(T) is proportional to the voltage value Vo as represented by Formula 5, the change rate of the magnetic permeability ⁇ r(T) is also large when the change rate of the voltage value Vo is large. So long as the Shore A hardness is not less than 10 and less than 50, the change of the voltage value Vo can be suppressed to 10% or smaller.
  • the lower limit of the Shore A hardness is more preferably 15%, still more preferably 18%.
  • the upper limit of the Shore A hardness is more preferably 48%.
  • the measurement method of the Shore A hardness is compliant with JIS2246.
  • the magnetic core unit of the present embodiment is suitably used in, for example, current transformers.
  • a current transformer of the present embodiment includes a magnetic core unit of the present embodiment and a coil.
  • a magnetic core unit is produced by the above-described magnetic core unit manufacturing method, and a wire is wound around the magnetic core unit, whereby a coil is formed around the magnetic core unit. Thereby, the current transformer is completed.
  • a molten alloy consisting of Cu: 1%, Nb: 3%, Si: 15%, B: 7%, and the remainder including Fe and unavoidable impurities (atomic %) was quenched by a single-roll method, resulting in a Fe-based amorphous alloy ribbon which had a width of 50 mm and a thickness of 18 ⁇ m.
  • the crystallization initiating temperature of this alloy measured by differential scanning calorimetry (DSC) was 500°C.
  • This Fe-based amorphous alloy ribbon was slit (cut) so as to have a width of 10 mm and thereafter wound up into a magnetic core element which had an outside diameter of 17 mm and an inside diameter of 12 mm (and a height of 10 mm).
  • the first heat treatment was performed on the produced magnetic core element in a temperature pattern shown in FIG. 12 .
  • the first heat treatment was performed in the absence of a magnetic field. Firstly, the temperature was increased to 450°C in 30 minutes, maintained at 450°C for 30 minutes, and then increased to the highest temperature in 240 minutes. This process was carried out for each of the highest temperatures of 520°C, 535°C, 540°C and 545°C. Thereafter, the temperature was maintained at the highest temperature for 60 minutes and then decreased to 350°C in 90 minutes. Thereafter, the magnetic core element was held in the furnace without being heated till it reached the room temperature. Thereby, a wound magnetic core of the nanocrystalline alloy was produced. This first heat treatment was performed in an atmosphere in which the oxygen concentration was not more than 10 ppm (2 ppm).
  • the second heat treatment was performed in a temperature pattern and a magnetic field application pattern shown in FIG. 13 .
  • the temperature was increased to 240°C in 60 minutes and maintained at 240°C for 30 minutes. The process until this point in time was carried out in the absence of a magnetic field. Thereafter, the temperature was decreased to 120°C in 60 minutes. A magnetic field of 159.5 kA/m was applied for 30 minutes since the decrease of the temperature was started. The direction of application of the magnetic field was the width direction of the alloy ribbon, i.e., the vertical direction of the core. Thereafter, the magnetic core was held in the furnace without being heated in the absence of a magnetic field till it reached the room temperature.
  • This second heat treatment was also performed in an atmosphere in which the oxygen concentration was not more than 10 ppm (2 ppm).
  • the magnetic permeability ⁇ core (25) was 500,000, the squareness ratio Br/Bm was 39.6%, and the saturated magnetostriction was 3 ppm.
  • the magnetic permeability ⁇ c ⁇ re (25) was 500,000, the squareness ratio Br/Bm was 46.9%, and the saturated magnetostriction was 2 ppm.
  • the magnetic permeability ⁇ core (25) was 668,000, the squareness ratio Br/Bm was 47.8%, and the saturated magnetostriction was 2 ppm.
  • the magnetic permeability ⁇ core (25) was 662, 000, the squareness ratio Br/Bm was 49.9%, and the saturated magnetostriction was 2 ppm.
  • FIG. 1 shows the magnetic permeability ⁇ core (-25), ⁇ core (25), ⁇ core (100) of the wound magnetic core measured at - 25°C, 25°C, 100°C as the change rate relative to ⁇ core (25).
  • Each of the wound magnetic cores for which the highest temperature of the first heat treatment was 520°C, 535°C, 540°C, and 545°C satisfies Formula 3 and Formula 4: 0 ⁇ ⁇ core ⁇ 25 ⁇ ⁇ core 25 / ⁇ core 25 ⁇ 0.25 ⁇ ⁇ core 100 ⁇ ⁇ core 25 / ⁇ core 25 ⁇ 0
  • 0.04 g, 0.05 g, or 0.06 g drops of an adhesive agent (SE9168RTV manufactured by TORAY-DOW CORNING (R), Shore A hardness: 44) ware applied to the layered surface (area: 132 mm 2 ) of the wound magnetic core, at 2, 3 or 4 positions separated at equal angular intervals.
  • an adhesive agent SE9168RTV manufactured by TORAY-DOW CORNING (R), Shore A hardness: 44
  • the wound magnetic core 13 was adhered to the body 14 of the case via the adhesive agent 16, and thereafter, the lid 12 was adhered to the body 14, resulting in a magnetic core unit 11.
  • the body 14 has the shape of an annular space 14a (trench) whose outside diameter is 25 mm, whose inside diameter is 8 mm, and whose height is 13 mm (each of them is an inner dimension).
  • the lid 12 is formed by a doughnut-like plate so as to close the opening of the body 14. Both the body 14 and the lid 12 are made of polyamide 66 (PA66).
  • the wound magnetic core was separated from the case after the adhesion.
  • the area in which the adhesive agent was applied was 48 mm 2 .
  • the area in which the adhesive agent was applied was 77 mm 2 .
  • the area in which the adhesive agent was applied was 86 mm 2 . In these cases, the area ratios of the adhesive agent are 36.4%, 58.3% and 65.2%.
  • FIG. 2 to FIG. 5 show the change rate of ⁇ unit (-25) and ⁇ unit (100) relative to the magnetic permeability ⁇ unit (25).
  • FIG. 2 shows the measurements in a magnetic core unit including a wound magnetic core which underwent the first heat treatment at 520°C.
  • FIG. 3 shows the measurements in a magnetic core unit including a wound magnetic core which underwent the first heat treatment at 535°C.
  • FIG. 4 shows the measurements in a magnetic core unit including a wound magnetic core which underwent the first heat treatment at 540°C.
  • FIG. 5 shows the measurements in a magnetic core unit including a wound magnetic core which underwent the first heat treatment at 545°C.
  • Each of the magnetic core units has excellent temperature characteristic so that the magnetic permeability ⁇ unit (T) satisfies Formula 1 and Formula 2.
  • T magnetic permeability ⁇ unit
  • FIG. 6 is a graph where the change rate of the magnetic permeability ⁇ unit (100) on the high temperature side (100°C) relative to ⁇ unit (25) was plotted over the area ratio of the adhesive agent (horizontal axis) for respective temperatures of the first heat treatment. As the temperature of the first heat treatment increases, the magnetic permeability ⁇ unit (100) decreases. For the magnetic core unit treated at 545°C, the decrease rate of the magnetic permeability of ⁇ unit (-25) relative to ⁇ unit (25) is -25.1% but does not exceed -28%.
  • ⁇ unit (-25) decreases relative to ⁇ unit (25) while ⁇ unit (100) increases.
  • the maximum difference in magnetic permeability is the sum of the decrease of ⁇ unit (-25) relative to ⁇ unit (25) and the increase of ⁇ unit (100). Therefore, this magnetic core unit is likely to have a large maximum difference in magnetic permeability. However, such a difference is allowable in consideration of the temperature characteristic required of a magnetic core unit for use in a current transformer.
  • FIG. 7 is a graph where the change rate of the magnetic permeability ⁇ unit (-25) on the low temperature side (-25°C) relative to ⁇ unit (25) was plotted over the area ratio of the adhesive agent (horizontal axis) for respective temperatures of the first heat treatment.
  • the change rate of the magnetic permeability of ⁇ unit (-25) is smaller than in a wound magnetic core in which the area ratio is more than 50%.
  • the change rate of the magnetic permeability ⁇ unit (25) after the magnetic core unit is maintained at 100°C for 100 hours is more than ⁇ 6% as will be described later. Therefore, if the magnetic core unit is required to undergo a small temporal change at high temperatures, it is preferred that the temperature of the first heat treatment is a still higher temperature.
  • the magnetic core units which include the wound magnetic cores on which the first heat treatment was performed at 535°C and 540°C have more excellent temperature characteristics, and the magnetic permeability ⁇ unit (T) satisfies Formula 1' and Formula 2'.
  • T magnetic permeability ⁇ unit
  • the change rate of at least one of ⁇ unit (-25) and ⁇ unit (100) relative to ⁇ unit (25) is greater than in the magnetic core units treated at 535°C and 540°C, although its decrease rate is suppressed to 28% or lower.
  • the first heat treatment in which the highest temperature was 540°C was performed on a magnetic core element. Thereafter, in the same way as in Example 1, the second heat treatment was performed in the temperature pattern and the magnetic field application pattern shown in FIG. 13 .
  • an adhesive agent SE9168RTV manufactured by TORAY-DOW CORNING (R), Shore A hardness: 44
  • the amount of the adhesive agent at each position was varied among 0.02 g, 0.03 g, 0.04 g, 0.05 g, and 0.06 g, and the adhesive agent was applied in 15 patterns in total.
  • This wound magnetic core was adhered to a case, resulting in a magnetic core unit shown in FIG.
  • the present inventor examined the relationship between the area ratio of the applied adhesive agent and the adhesion strength (tensile strength) between the wound magnetic core and the case and found such a tendency that the adhesion strength improves as the area ratio of the adhesive agent increases as shown in FIG. 14 .
  • an adhesive agent was applied at 2 positions separated at equal angular intervals, and the amount of the adhesive agent at each position was varied between 0.02 g and 0.06 g. In these samples, the change rate of ⁇ unit (-25) and ⁇ unit (100) relative to ⁇ unit (25) of the magnetic core unit was examined.
  • the case and the wound magnetic core were separated from the magnetic core unit, and the area ratio of the adhesive agent was measured.
  • the area ratio of the adhesive agent was 31.7%.
  • the area ratio of the adhesive agent was 39.8%.
  • FIG. 8 is a graph where the change rate of the magnetic permeability ⁇ unit (25) after the magnetic core unit was maintained at 100°C for 100 hours (hereinafter, referred to as "high temperature temporal change rate ⁇ ") was plotted for respective temperatures of the first heat treatment.
  • the horizontal axis represents the area ratio of the adhesive agent.
  • the vertical axis represents the high temperature temporal change rate ⁇ .
  • the area ratio of the adhesive agent (SE9168RTV manufactured by TORAY-DOW CORNING (R), Shore A hardness: 44) on the layered surface of the wound magnetic core was 31.6%, 36.4%, 58.5% or 65.2%.
  • TABLE 3 shows the numerical values of the points plotted in FIG. 8 .
  • the area ratio of the adhesive agent is more than 50%
  • the high temperature temporal change rate ⁇ is more than ⁇ 6% in some of the magnetic core units.
  • the high temperature temporal change rate ⁇ was not more than 6%.
  • the manufacturing method in order to manufacture a magnetic core unit in which the high temperature temporal change rate ⁇ is within 6%, such a manufacturing method is preferred that (1) the area ratio of the adhesive agent is not more than 50%, or (2) the highest temperature of the first heat treatment is equal to or higher than 530°C (535°C, 540°C, 545°C). Considering the variation in characteristics due to mass production, it can be said that the manufacturing method preferably meet both of the conditions (1) and (2).
  • FIG. 11 is a graph showing the relationship between the highest temperature in the second heat treatment in the presence of an applied magnetic field (in FIG. 13 , a temperature at which application of the magnetic field is started during decrease of the temperature) (horizontal axis) and the magnetic permeability ⁇ unit (25) of the wound magnetic core after the second heat treatment (vertical axis).
  • the magnetic permeability ⁇ unit (25) of not less than 400000 and not more than 700000 can be achieved by setting the highest temperature of the second heat treatment in the presence of an applied magnetic field to a temperature in the range of not less than 225°C and not more than 270°C.
  • the lower limit of this highest temperature is 230°C, a wound magnetic core whose magnetic permeability ⁇ unit (25) is not less than 400000 is easily realized.
  • the upper limit is 265°C, a wound magnetic core whose magnetic permeability ⁇ unit (25) is not more than 700000 is easily realized.
  • the Fe-based amorphous alloy ribbon used was the same as that of Example 1 (alloy composition consisting of Cu: 1%, Nb: 3%, Si: 15%, B: 7%, and the remainder including Fe and unavoidable impurities (atomic %), width: 50 mm, thickness: 18 ⁇ m).
  • This Fe-based amorphous alloy ribbon was slit (cut) so as to have a width of 6 mm and thereafter wound up into a magnetic core element which had an outside diameter of 20 mm and an inside diameter of 10 mm (and a height of 10 mm).
  • the first heat treatment was performed on the produced magnetic core element.
  • the first heat treatment was performed in the absence of a magnetic field. Firstly, the temperature was increased to 450°C in 30 minutes, maintained at 450°C for 30 minutes, and then increased to 530°C in 240 minutes, which was the highest temperature. Thereafter, the magnetic core element was maintained at the highest temperature for 60 minutes and then cooled to the room temperature.
  • the second heat treatment was performed. First, the temperature was increased to 250°C in 60 minutes and maintained at 250°C for 30 minutes. The process until this point in time was carried out in the absence of a magnetic field. Thereafter, the temperature was decreased to 150°C in 60 minutes. A magnetic field of 159.5 kA/m was applied for 30 minutes since the decrease of the temperature was started. The direction of application of the magnetic field was the width direction of the alloy ribbon, i.e., the vertical direction of the core. Thereafter, the magnetic core element was held in the furnace without being heated in the absence of a magnetic field till it reached the room temperature. This second heat treatment was performed in an atmosphere in which the oxygen concentration was not more than 10 ppm (2 ppm). Thereby, a wound magnetic core of the nanocrystalline alloy was produced.
  • an adhesive agent was applied at 4 positions separated at equal angular intervals.
  • the amount of the adhesive agent at each position was 0.02 g.
  • the adhesive agents used had Shore A hardness of 20, 44, 50 and 70 (Samples A to D).
  • the adhesive agent of Sample B was used for preparing three magnetic core units.
  • Each of the other adhesive agent samples was used for preparing two magnetic core units.
  • the voltage value Vo(V) was measured by the digital multimeter (DMM) 56 in the measurement system of FIG. 16 , and the change rate of the voltage value Vo(V) was calculated.
  • the measurement results are shown in TABLE 4.
  • the temperature characteristic improves when the coercivity is small.
  • the present inventor examined whether or not the coercivity Hc can be reduced by changing the temperature rise rate in a temperature range at which nanocrystallization begins.
  • the temperature rise rate from 450°C to 530°C that was the highest temperature was 0.375°C/min, 0.5°C/min, 0.75°C/min, 1°C/min, 1.5°C/min, 2°C/min or 3°C/min.
  • the other conditions were the same as those of Example 6 in manufacturing a magnetic core unit.
  • the coercivity Hc of the resultant magnetic core unit was measured.
  • FIG. 17 shows the results of measurement of ( ⁇ core (100) - ⁇ core (25)) / ⁇ core (25) of the wound magnetic core in varying temperature patterns of the first heat treatment and the second heat treatment. It was confirmed that, in a wound magnetic core produced by the two-step heat treatment, the temperature characteristic represented by ( ⁇ core (100) - ⁇ core (25)) / ⁇ core (25) is likely to decrease as the coercivity decreases.
  • ( ⁇ core (100) - ⁇ core (25)) / ⁇ core (25) of the wound magnetic core can be set to the range of not less than -25% and less than 0% by setting the coercivity Hc in the range of not less than 0.4 A/m and not more than 0.75 A/m. It is also seen that ( ⁇ c ⁇ re (100) - ⁇ core (25)) / ⁇ core (25) of the wound magnetic core can be set in a more preferred range of not less than -20% and not more than -5% by setting the coercivity Hc in the range of not less than 0.5 A/m and not more than 0.65 A/m.
  • FIG. 18 is a graph showing the relationship between the temperature rise rate and the coercivity of the wound magnetic core.
  • the coercivity Hc of the wound magnetic core is not less than 0.4 A/m and not more than 0.75 A/m.
  • the range of ( ⁇ core (100) - ⁇ c ⁇ re (25))/ ⁇ core (25) of the wound magnetic core can be easily set to -0.25 ⁇ ( ⁇ core (100) - ⁇ core (25))/ ⁇ core (25) ⁇ 0.
  • the coercivity Hc of the wound magnetic core is not less than 0.4 A/m and not more than 0.65 A/m.
  • the range of ( ⁇ core (100) - ⁇ core (25))/ ⁇ core (25) of the wound magnetic core can be easily set to -0.20 ⁇ ( ⁇ core (100) - ⁇ core (25))/ ⁇ core (25) ⁇ -0.05.
  • the coercivity Hc is generally equal to the value achieved at 0.375°C/min, and when the temperature rise rate is in the range of not less than 0.375°C/min and not more than 1.2°C/min, the coercivity Hc reaches a minimum value.
  • the wound magnetic core can be stably manufactured in a further narrowed range of ( ⁇ core (100) - ⁇ core (25))/ ⁇ core (25) of the wound magnetic core. If the upper limit of the temperature rise rate is 1.0°C/min, the coercivity Hc can be further reduced.
  • a magnetic core unit of the present disclosure is suitably usable for a magnetic core of common mode choke coils, high frequency transformers, pulse transformers, current transformers, etc., and can be suitably used in, for example, a current transformer.

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Claims (10)

  1. Unité à noyau magnétique comprenant :
    un noyau magnétique enroulé comportant un ruban enroulé en alliage nanocristallin ;
    un boîtier possédant un espace correspondant à une forme externe du noyau magnétique enroulé, le noyau magnétique enroulé étant logé dans l'espace; et
    un agent adhésif prévu entre une surface inférieure de l'espace et une surface stratifiée du noyau magnétique enroulé, l'agent adhésif faisant coller le noyau magnétique enroulé à la surface inférieure,
    dans laquelle le ruban en alliage nanocristallin possède une magnétostriction saturée supérieure à 1 ppm, et
    la perméabilité magnétique µunit(25) n'est pas inférieure à 400000 et la formule 1' et la formule 2' sont satisfaites : − 0,20 ≤ μ unit 100 − μ unit 25 / μ unit 25 ≤ 0
    Figure imgb0028
     − 0,20 ≤ μ unit − 25 − μ unit 25 / μ unit 25 ≤ 0
    Figure imgb0029
    où µunit(T) est une perméabilité magnétique mesurée à la température T°C en présence d'un champ magnétique de fréquence à CA f=50 Hz et d'amplitude H=1,0 ampère/mètre (A/m) appliqué à travers le noyau magnétique enroulé collé au boîtier,
    dans lequel le ruban d'alliage nanocristallin est fabriqué en un alliage qui possède une composition représentée par la formule : (Fe1-aMa)100-x-y-z-α-β-γCuxSiyBzM'αM"βXγ (% atomique) (M est du Co et/ou du Ni, M' est au moins un élément sélectionné à partir du groupe se composant du Nb, du Mo, du Ta, du Ti, du Zr, du Hf, du V, du Cr, du Mn et du W, M" est au moins un élément sélectionné à partir du groupe se composant de l'Al, des éléments du groupe du platine, du Sc, des éléments des terres rares, du Zn, du Sn et du Re, X est au moins un élément sélectionné à partir du groupe se composant du C, du Ge, du P, du Ga, du Sb, de l'In, du Be, et de l'As, a, x, y, z, α, β et γ obéissent respectivement à 0≤a≤0,5, à 0,1≤x≤3, à 0≤y≤30, à 0≤z≤25, à 5≤y+z≤30, à 0≤α≤20, à 0≤β≤20 et à 0≤γ≤20), et
    caractérisée en ce que
    la surface stratifiée du noyau magnétique enroulé est collée au boîtier par l'agent adhésif dans une plage non inférieure à 30 % et non supérieure à 50 % par rapport à une zone de la surface stratifiée du noyau magnétique enroulé.
  2. Unité de noyau magnétique selon la revendication 1, dans laquelle un taux de changement Δµ entre la perméabilité magnétique µunit(25) avant que l'unité de noyau magnétique soit maintenue à 100 °C pendant 100 heures et la perméabilité magnétique µunit(25) après que l'unité de noyau magnétique soit maintenue à 100 °C pendant 100 heures est dans les limites de ±6 %.
  3. Unité de noyau magnétique selon la revendication 1 ou 2, dans laquelle la perméabilité magnétique µunit(25) n'est pas supérieure à 700000.
  4. Unité de noyau magnétique d'une quelconque des revendications 1 à 3, dans laquelle l'agent adhésif possède une dureté Shore A non inférieure à 10 et inférieure à 50.
  5. Transformateur de courant comprenant l'unité de noyau magnétique telle que définie dans une quelconque des revendications 1 à 4.
  6. Méthode de fabrication d'une unité à noyau magnétique, comprenant :
    la livraison d'un élément de noyau magnétique formé par l'enroulement d'un ruban en alliage amorphe, l'élément de noyau magnétique possédant une composition représentée par la formule : (Fe1-aMa)100-x-y-z-α-β-γCuxSiyBzM'αM"βXγ (% atomique) (M est du Co et/ou du Ni, M'est au moins un élément sélectionné à partir du groupe se composant du Nb, du Mo, du Ta, du Ti, du Zr, du Hf, du V, du Cr, du Mn et du W, M" est au moins un élément sélectionné à partir du groupe se composant de l'Al, des éléments du groupe du platine, du Sc, des éléments des terres rares, du Zn, du Sn et du Re, X est au moins un élément sélectionné à partir du groupe se composant du C, du Ge, du P, du Ga, du Sb, de l'In, du Be, et de l'As, a, x, y, z, α, β et γ obéissent respectivement à 0≤a≤0,5, à 0,1≤x≤3, à 0≤y≤30, à 0≤z≤25, à 5≤y+z≤30, à 0≤α≤20, à 0≤β≤20 et à 0≤γ≤20) ;
    la production d'un noyau magnétique enroulé en effectuant un premier traitement thermique et un second traitement thermique sur l'élément de noyau magnétique, le premier traitement thermique comprenant le chauffage à une température égale ou supérieure à une température de lancement de cristallisation en l'absence d'un champ magnétique, le second traitement thermique comprenant le chauffage à une température inférieure à la température de lancement de cristallisation, le second traitement thermique comprenant l'application d'un champ magnétique dans une direction perpendiculaire à un chemin magnétique, le noyau magnétique enroulé possédant une magnétostriction saturée supérieure à 1 ppm, une perméabilité magnétique µcore(25) étant non inférieure à 400000, et la formule 3 et la formule 4' étant satisfaites : 0 < μ core − 25 − μ core 25 / μ core 25
    Figure imgb0030
     − 0,20 ≤ μ core 100 − μ core 25 / μ core 25 < − 0,05
    Figure imgb0031
    où µcore(T) est une perméabilité magnétique mesurée à la température T°C en présence d'un champ magnétique de fréquence à CA f=50 Hz et d'amplitude H=1,0 ampère/mètre (A/m) appliqué à travers le noyau magnétique enroulé; et
    la livraison d'un agent adhésif entre un boîtier et une surface en couches du noyau magnétique enroulé pour coller le noyau magnétique enroulé au boîtier, le boîtier possédant un espace qui correspond à une forme externe du noyau magnétique enroulé,
    dans lequel une température la plus élevée du premier traitement thermique est égale ou supérieure à 530 °C et inférieure à 545 °C,
    caractérisée en ce que
    l'agent adhésif est présent sur la surface stratifiée du noyau magnétique enroulé dans une plage non inférieure à 30 % et non supérieure à 50 % par rapport à une zone de la surface stratifiée du noyau magnétique enroulé pour coller le noyau magnétique enroulé au boîtier.
  7. Méthode selon la revendication 6, dans laquelle une température la plus élevée du second traitement thermique est égale ou supérieure à 225 °C et inférieure à 270 °C.
  8. Méthode selon la revendication 6 ou 7, dans laquelle, dans le premier traitement thermique, un taux d'augmentation de température à la température de lancement de la cristallisation n'est pas supérieur à 5 °C/min.
  9. Méthode selon une quelconque des revendications 6 à 8, dans laquelle l'agent adhésif possède une dureté Shore A non inférieure à 10 et inférieure à 50.
  10. Méthode de fabrication d'un transformateur de courant, comprenant :
    la fabrication d'une unité à noyau magnétique par la méthode de fabrication d'unité de noyau magnétique telle que définie dans une quelconque des revendications 6 à 9 ; et
    l'enroulement d'un fil autour de l'unité à noyau magnétique.
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DE102007034532A1 (de) * 2007-07-24 2009-02-05 Vacuumschmelze Gmbh & Co. Kg Magnetkern, Verfahren zu seiner Herstellung sowie Fehlerstromschutzschalter
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