JP2018125475A - Laminate iron core, manufacturing method of the same, and electromagnetic component using the laminate iron core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate iron core having uniform magnetic characteristic, an electromagnetic component using the laminate iron core, and a manufacturing method of the laminate iron core by using a nano crystal ribbon.SOLUTION: A laminate iron core is a laminate iron core 10 that constructs one nano magnetic layer by combining a plurality of nano crystal ribbons 102a to 102f in connection surfaces 11a to 11c, and in which a nano magnetic layer is laminated. In a plan surface view where the laminate iron core 10 is viewed from a laminate direction, the connection surfaces 11a to 11c are positioned in a plurality of lines, and are distributed in a point symmetry. Also, a manufacturing method of the laminate iron core, includes: a first step of manufacturing an amorphous ribbons; a second step of externally processing the amorphous ribbons of the first step; a third step of thermally processing the amorphous ribbons obtained by externally processing in the second step, and obtaining the nano crystal ribbon; and a fourth step of laminating the plurality of nano crystal ribbons in the third step as a combination one layer.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a laminated iron core, a manufacturing method thereof, and an electromagnetic component using the laminated iron core.

  As shown in the perspective view of FIG. 8, the conventional laminated iron core 100 is configured by laminating thin plates 106 such as silicon steel strips which are magnetic materials. The laminated core 100 has a coil wound around it, and is used for a small transformer, a reactor, a current transformer, a pole transformer, and the like.

  On the other hand, there are amorphous alloy ribbons and nanocrystal ribbons with excellent magnetic properties. In order to obtain a nanocrystal ribbon with high magnetic properties, it is necessary to form a nano-level crystal. For this purpose, the raw material solution is quenched and thinned (Patent Document 1), and then heat treatment is performed. As a result, nanocrystals are deposited. This manufacturing method will be described with reference to the cross-sectional view of FIG.

  Magnetic material melted from the nozzle 103 is applied to the roller 101. The roller 101 is cooled and receives the solution while rotating. The solution is quenched at the surface to produce a ribbon. At this point, the ribbon is an amorphous ribbon 13. Although the amorphous ribbon 13 has different heat treatment conditions, a nanocrystal ribbon having nano-level crystal grains can be produced by heat treatment at a predetermined temperature and time.

Japanese Patent Laid-Open No. 2001-1113

  However, a nanocrystal ribbon having a wide width or a long length cannot be produced from the amorphous ribbon 13. This is because the size of the roller 101 in FIG. 9 is limited. Moreover, when producing a uniform nanocrystal ribbon by the method of FIG. 9, the width cannot be increased or the length cannot be increased. If the width or length is increased, the homogeneity will deteriorate. Furthermore, even in the subsequent heat treatment, if the width or length is increased, the temperature control greatly affects the characteristics, and a homogeneous product cannot be produced. As a result, it is difficult to produce a nanocrystal ribbon having a wide width or a long length.

  For this reason, it is necessary to manufacture many amorphous ribbons 13 having a short width or a short length, heat-treat them to be nanocrystallized, and add and wind them in order. Since the added portion becomes discontinuous in magnetic characteristics with other portions, the magnetic characteristics are non-uniform as a whole. The magnetic characteristics mainly indicate soft magnetic characteristics.

  Therefore, the present invention solves the above-mentioned conventional problems, and provides a laminated core having a uniform magnetic property using a nanocrystalline ribbon, an electromagnetic component using the laminated core, and a method for producing the laminated core It is.

  In order to achieve the above object, a plurality of nanocrystal ribbons are combined at a connecting surface to form a single nanomagnetic layer, and the laminated magnetic core is formed by laminating the nanomagnetic layer. In the viewed plan view, the connecting surface is positioned by a plurality of lines, and uses a laminated iron core that is distributed point-symmetrically.

  Moreover, the electromagnetic component which wound the coil around the said laminated iron core is used.

  Furthermore, a first step for producing an amorphous ribbon, a second step for externally processing the amorphous ribbon in the first step, and a heat treatment of the amorphous ribbon that has been externally processed in the second step to heat the nanocrystalline ribbon. And a fourth step of laminating as a single layer a combination of the plurality of nanocrystal ribbons in the third step.

  According to an example of the present invention, it is possible to provide a laminated iron core having uniform magnetic characteristics and a component using the laminated iron core. Further, according to another example, it is possible to provide a component having uniform magnetic characteristics.

The figure which shows the manufacture flow of the laminated iron core in Embodiment 1 (A) Exploded perspective view of laminated core in Embodiment 1, (b) (a) plan view, (c) (a) side view, (d) (b) plan view showing a modification example (A) Perspective view of the ribbon of Embodiment 2, (b) Plan view showing a portion from which the ribbon is extracted from (a), (c) (b) shows a state in which the ribbons extracted are combined. Plan view, enlarged sectional view of the connecting surface portion of the ribbon of (d) (c) (A)-(c) Side view of laminated thin ribbon of embodiment 2 (A)-(c) The top view which shows the connection surface of the ribbon of Embodiment 3, (d) The top view of the laminated iron core at the time of (b) (A)-(b) Exploded perspective view of the laminated ribbon of Embodiment 4, (c)-(e) Plan view showing division of the ribbon for producing the laminate of (b) The figure which shows the flow of manufacture of the lamination | stacking thin ribbon of Embodiment 5. Perspective view of conventional laminated iron core Sectional drawing which shows the manufacturing method of the conventional ribbon

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

(Embodiment 1)
<Manufacture of laminated core>
An example of the manufacturing method of a laminated iron core is shown in FIG.
(1) Amorphous ribbon production As described with reference to FIG. 9, an alloy melt of a magnetic material is applied from the nozzle 103 to the surface of the cooled roller 101. The melt is rapidly cooled to form an amorphous ribbon 13.

In particular, it is preferable to use an Fe-B-Cu alloy, an Fe-Cu-Nb-Si-B alloy, or an Fe-BP-Cu alloy. The thickness of the amorphous ribbon 13 is about 10 to 50 μm on average.
(2) Processing The amorphous ribbon 13 of (1) is processed so as to have a predetermined outer shape. The external shape varies depending on conditions.
(3) Heat treatment The amorphous ribbon 13 processed in (2) is heat treated. The heat treatment is preferably performed at a high speed. As a result, a nanocrystalline ribbon with good soft magnetic properties can be produced. Since the amorphous ribbon 13 of (2) is not long and is short, it can be heated at high speed in a furnace or the like.

Heat to a temperature slightly higher than the crystallization temperature of the alloy composition.
(4) Lamination A plurality of nanocrystal ribbons produced by the heat treatment of (3) are laminated.
(5) Integration A resin is inserted into the laminated nanocrystal ribbons or put into an outer frame to produce a laminated core. Here, the production of the laminated iron core and the production of the nanocrystal ribbon are examples, and other production methods of the nanocrystal ribbon may be used.

<Structure of laminated core>
The laminated iron core 10 of Embodiment 1 will be described with reference to FIGS. 2 (a) to 2 (c). FIG. 2A is a development view of the laminated core 10. FIG. 2B is a plan view of the laminated core 10. FIG. 2C is a side view of the laminated core 10.

  In this example, six nanocrystal ribbons 102a to 102f are used as two nanosheets, and a set of three layers and three layers are shown as one nanomagnetic layer. Each of the three nanomagnetic layers A, B, and C has two connecting surfaces 11a, 11b, and 11c. When the nanocrystal ribbon and the connection surface are not specified, the nanocrystal ribbon 102 and the connection surface 11 are expressed.

  As described above, the nanocrystal ribbon 102 of the embodiment is a child piece punched in (2). When the laminated core 10 is viewed from above in the lamination direction, the connecting surface 11 appears as a line. Each line meets at an angle of 90 degrees. The distribution of the line segments is distributed point-symmetrically.

As a modification of FIG. 2B, a connecting surface 11 as shown in the plan view of FIG.
That is, the angle θ formed by a plurality of line segments connecting each connecting surface 11 is substantially equal. As a result, the magnetic properties of the laminated core 10 are uniform. In the plan view, the same number of upper and lower connecting surfaces is preferable. In the example of FIG. 2A to FIG. 2C, there are two and one connecting surfaces 11 depending on the location. This is preferably a four-layer structure with the same number of two.

  In this example, each nanocrystal ribbon 102 has substantially the same thickness and shape. Moreover, although the nanocrystal ribbon 102 has a half shape of a donut, it may be a third, a frame shape, or a half thereof.

  The line of the connecting surface 11 is preferably point-symmetric, but may be line-symmetric.

(Embodiment 2)
The second embodiment will be described with reference to FIGS. 3 (a) to 3 (d). The second embodiment differs from the first embodiment in the structure of the connecting surface 11 between the nanocrystal ribbons 102. Matters not described are the same as those in the first embodiment.

  FIG. 3A is a perspective view of the nanocrystal ribbon 102. The nanocrystal ribbon 102 produced by the above method has a thickness variation. This is because, as described with reference to FIG. 9, both surfaces of the nanocrystal ribbon 102 are cooled without being pressurized. The thickness variation is at most 20 μm to 50 μm.

  In the case of FIG. 3A, the thickness increases in the order of point A, point B, point C, and point D. Here, as an example, the nanocrystalline ribbon 102a and the nanocrystalline ribbon 102b are produced from the nanocrystalline ribbon 102 as shown in the plan view of FIG. FIG. 3C shows a plan view of the connecting surface 11 and each of the nanocrystal ribbons 102a and 102b. The thicknesses of the nanocrystal ribbons 102 are different at the points a, b, c, and d on the connecting surface 11 of each nanocrystal ribbon 102. Here, the thickness of the nanocrystal ribbon 102 at the points a, b, c, and d decreases in the order of the points a, b, c, and d.

  In this case, an enlarged sectional view of the connecting surface 11 is shown in FIG. Match point a and point d. Moreover, the point b and the point c are match | combined. By doing in this way, the thickness dispersion | variation (thickness difference) in each point of the connection surface 11 reduces. That is, the average value of the thickness of the point a and the point d is matched with the average value of the thickness of the point b and the point c. In other words, the thickest point and the thinnest point of the four points are matched at one end, and the other points are matched at the other end. The average thickness is an average value of the thicknesses of the two nanocrystal ribbons 102 on the connecting surface 11.

  With this relationship, side views corresponding to FIG. 2C are shown in FIGS. 4A to 4C.

  In FIG. 4A, the point a and the point d are aligned in the nanomagnetic layer A, and the point b and the point c are aligned in the nanomagnetic layer C.

  In FIG. 4B, the point a and the point d are aligned in the nanomagnetic layer A, and the point d and the point a are aligned in the nanomagnetic layer C.

  In FIG. 4C, the point a and the point d are matched in the nanomagnetic layer A, and the point a and the point d are matched in the nanomagnetic layer C.

  From the viewpoint of symmetry, the connecting surface 11 is preferably uniform and random. Either may be used, but it is preferable in the order of FIG. 4C, FIG. 4B, and FIG.

  That is, the nanomagnetic layer A having the maximum average thickness at the connecting surface 11 and the nanomagnetic layer C having the minimum average thickness at the connecting surface are combined. As a result, the average thickness is averaged at the upper and lower connecting surfaces 11. Of course, the nanomagnetic layers A and C may be reversed.

  It is preferable to reduce the variation in the average thickness of the nanocrystalline ribbon 102 at the connecting surface between the upper and lower portions of each layer.

(Embodiment 3)
A third embodiment will be described with reference to FIGS. 5 (a) to 5 (c). The third embodiment is different from the first embodiment in the structure of the connecting surface 11 between the nanocrystal ribbons 102. Matters not described are the same as in the first and second embodiments. FIG.5 (d) is a top view of the laminated iron core at the time of FIG.5 (b). The shape of the connecting surface 11 changes in FIGS. 5 (a) to 5 (c).

  FIG. 5A is a plan view of the connecting surface 11 between the nanocrystal ribbon 102a and the nanocrystal ribbon 102b. The nanocrystal ribbons 102a and 102b both have uneven edges. Combine the two. When attention is paid to the connecting surface 11, it becomes a staircase shape.

  FIG. 5B is a plan view of the connecting surface 11 between the nanocrystal ribbon 102a and the nanocrystal ribbon 102b. The nanocrystal ribbons 102a and 102b both have inclined sides. When attention is paid to the connecting surface 11, an inclined connecting surface and a parallelogram are formed.

  FIG. 5C is a plan view of the connecting surface 11 between the nanocrystal ribbon 102a and the nanocrystal ribbon 102b. The nanocrystal ribbons 102a and 102b both have wavy edges. Even if attention is paid to the connecting surface 11, it is wavy.

  In any of the above, the two ends of the nanocrystal ribbons 102a and 102b are combined into one shape. In addition to the above, the edge may have a jagged shape.

  The shape of the connecting surface 11 of the nanocrystal ribbon 102 should not be symmetrical between the two nanocrystal ribbons 102. The influence of the thickness variation of the nanocrystal ribbon 102 is reduced, and the homogeneity increases as a whole.

  In addition, the line segment of the connection surface 11 shown in Embodiment 1 is a line segment shown with a dotted line in this example. The line segments are preferably distributed symmetrically.

(Embodiment 4)
The fourth embodiment relates to the shape of each nanocrystalline ribbon 102 of the laminated core 10. The fourth embodiment will be described with reference to FIGS. 6 (a) to 6 (e). Matters not described are the same as in the first to third embodiments.

  In the perspective view of FIG. 6A, each nanocrystal ribbon 102 has a shape that is half the edge of the frame. Two nanocrystal ribbons are laminated as combination layers (nanomagnetic layers A to C). The connecting surface 11 is the same as that in FIG.

  In the perspective view of FIG. 6B, four nanocrystal ribbons 102 are combined to form one nanomagnetic layer A to C. The rectangular nanocrystal ribbons 102b and 102d are combined with the shaped nanocrystal ribbons 102a and 102c.

  In FIG. 6B, the line segment of the connecting surface 11 shown in the first embodiment is a line segment indicated by a dotted line in this example. The line segments are preferably distributed symmetrically.

  The advantage of this shape is that the use efficiency of the nanocrystal ribbon is good. In order to obtain such a shape, as shown in the plan views of FIG. 6C to FIG. 6E, rectangular nanocrystal ribbons 102b and 102d can be formed from one nanocrystal ribbon 102 without waste. The character-shaped nanocrystal ribbons 102a and 102c can be taken out.

(Embodiment 5)
The fifth embodiment relates to selection of the nanocrystal ribbon 102. Embodiment 5 will be described with reference to FIG. Matters not described are the same as in the first to fourth embodiments.

FIG. 7 is a flow for manufacturing the laminated core 10.
(1) Production of nanocrystalline ribbon The process up to the heat treatment of FIG. A plurality of nanocrystal ribbons 102 having a certain shape are produced.
(2) Measurement of the thickness of the nanocrystal ribbon 102 The thickness of the portion that becomes the connecting surface of the nanocrystal ribbon 102 of (1) is measured.
(3) Determination of the combination of nanocrystalline ribbons From the result of the thickness measurement in (2), the combination of nanocrystalline ribbons 102 is determined so that the average thickness at the connecting surface is reduced.
(4) Combination and lamination The combination of the nanocrystal ribbons 102 determined in (3) is combined and laminated.
As an example, consider a case where a laminated core 10 having a shape as shown in FIG.
A plurality of nanocrystal ribbons 102 are produced, and the thicknesses of two portions of the joining surface 11 portion of each nanocrystal ribbon 102 are measured. The nanocrystal ribbons 102 are arranged in the order of the two average thicknesses, and are combined in that order. The combination is performed as shown in FIGS. 3C and 3D. One combination layer is produced and laminated. By doing so, the thickness variation between layers is reduced.

(as a whole)
The above embodiments can be combined.
When a coil is wound around the laminated core 10, it becomes an electromagnetic component, and a device that uses various electromagnetic waves.

  You may protect the connection surface 11 with a protection part. The protective part may be protected by a resin, a resin tape, or the like. Not only the connecting surface 11 but also the whole may be molded protected with resin or the like.

  The laminated iron core of the present invention can be used for small transformers, reactors, current transformers, pole transformers, motors and the like.

DESCRIPTION OF SYMBOLS 10 Laminated iron core 11, 11a, 11b, 11c Connecting surface 13 Amorphous thin ribbon 100 Laminated iron core 101 Roller 102 Nanocrystalline ribbon 102a Nanocrystalline ribbon 102b Nanocrystalline ribbon 103 Nozzle 106 Thin plate

Claims (11)

A laminated iron core in which a plurality of nanocrystalline ribbons are combined at a connecting surface to form one nanomagnetic layer, and the nanomagnetic layer is laminated,
In the plan view of the laminated iron core as viewed from the direction of the lamination, the connecting surfaces are located in a plurality of lines and are distributed symmetrically with respect to a point. The laminated core according to claim 1, wherein an angle formed between the plurality of lines is a constant angle. In the nanomagnetic layer, there are a plurality of the joining surfaces, and the nanocrystal thin film is formed such that an average value of the thicknesses of the two nanocrystal ribbons at each joining surface becomes smaller in the nanomagnetic layer. The laminated iron core according to claim 1 or 2, wherein bands are combined. When there are two joint surfaces, the nanocrystal ribbon having the maximum thickness and the nanocrystal ribbon having the minimum thickness are combined at the four thicknesses of the nanocrystal ribbon at the two locations. The laminated iron core according to claim 3, wherein the two nanocrystalline ribbons are combined. Between the plurality of nanomagnetic layers, in the plan view from the stacking direction, as the upper and lower connecting surfaces, the average thickness between the nanocrystal ribbons is the minimum connecting surface in one of the nanomagnetic layers. The laminated iron core according to any one of claims 1 to 4, wherein the connecting surface that is the largest of the other nanomagnetic layers is combined. The laminated iron core according to any one of claims 1 to 5, wherein end faces of the combined nanocrystal ribbons are not the same shape. The laminated iron core according to any one of claims 1 to 5, wherein the nanomagnetic layer is formed by combining the character-shaped nanocrystal ribbon and the square nanocrystal ribbon. The laminated iron core according to claim 1, wherein the nanomagnetic layer has a donut shape or a frame shape. The electromagnetic component which wound the coil around the laminated core of any one of Claims 1-8. A first step of producing an amorphous ribbon;
A second step of externally processing the amorphous ribbon in the first step;
A third step of heat-treating the amorphous ribbon subjected to the external processing in the second step to form a nanocrystalline ribbon;
And a fourth step of laminating the plurality of nanocrystal ribbons in the third step as a combined layer. The fourth step includes
A fifth step of measuring the thickness of the nanocrystal ribbon;
A sixth step of determining a combination of the nanocrystal ribbons from the thickness of the fifth step;
11. A laminated core according to claim 10, comprising: forming a layer combining the nanocrystalline ribbons by a combination of the sixth step, forming a plurality of layers by repeating, and laminating the plurality of layers. Manufacturing method.

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