TW508595B - Magnetic core insulation - Google Patents

Abstract

Disclosed herein is an insulating material between adjacent metal layers of a soft magnetic core, and a process for forming this insulating material. The insulating material is composed of the native metal oxides of the metallic core material. A method of providing dielectric isolation between adjacent metal layers of a laminated magnetic assembly, comprising: providing a laminated magnetic assembly having a plurality of layers, wherein the layers are formed in part of iron; and oxidizing the layers to produce an insulative coating comprising iron oxide between the layers, the resulting oxidized magnetic assembly exhibiting power losses reduced by at least 15% in comparison to a substantially identically dimensioned assembly without the insulative coating at an operating frequency of 10 kHz to 20 kHz.

Description

508595 A7

Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs 5. Description of the invention () Invention collar: The present invention relates generally to a method for insulating between adjacent metal layers of a magnetic core, and a soft magnetic core produced by the method . In particular, the invention relates to the formation and use of natural metal oxides between adjacent metal magnetic core layers as insulation between the layers to limit the current flow. Rather, the method of the present invention can be used to adjust the magnetic characteristics of a core formed using the present invention. BACKGROUND OF THE INVENTION: Magnetic materials come in at least two forms, hard or soft. Hard magnetic materials are permanent magnets that retain their magnetic properties even after the excitatory magnetic field is removed. An example of a hard magnetic material is a general refrigerator magnet. Conversely, the magnetic field of the 'soft magnetic material' disappears after the excitation energy field is removed. For example, soft magnetic materials include electromagnets. Soft magnetic materials are a large number of circuits used in components such as transformers' inductors, inverters, switching power supplies, and other applications. The soft magnetic material is also used as a magnetic core, which provides high energy storage, fast energy storage and effective energy recovery. In these applications, the core can be used in a variety of different operating frequencies, ranging from 50Hz to 20kHz or higher. Most magnetic cores are formed by tightly winding a thin magnetic metal strip around a substrate to form a multilayer stack. The wound metal core is then subjected to a heating step called tempering to optimize its performance by thermally sequencing magnetic turns in the metal. After the tempering step, the substrate can be removed and the magnetic core can be treated with an adhesive to join adjacent metal layers together so that the core does not fall apart. As known to those skilled in the art, this adhesive can contain ------- »I --- u I (Please read the precautions on the back before filling this page)%-Page 2

508595 A7 B7 V. Description of the invention () One or two parts of epoxy resin, such as Hyss 1 # 4 2 4 2 resin and # 340 1 hardener, or # 2076 impregnated epoxy resin . The treatment with an adhesive also allows the core to be formed into a C-shaped or E-shaped core by cutting treatment, so named because the cutting core forms a C or E as known to those skilled in the art. The metal strip or layer used as the magnetic core is very thin, and is typically formed to a thickness of about 0.1 to 0.3 mm. For high frequency applications greater than 400Hz, the individual metal layers of a wound core must be electrically insulated from each other at the same time for proper operation. Without upper insulation, at high frequencies, the magnetic core has electrical characteristics similar to large metal blocks and will cause a large amount of power loss due to full current. In order to provide insulation between layers, the prior art teaches that the metal tape is coated with an insulating material before the core is wound around the tape. Insulating materials are typically applied to both sides of the tape and act to insulate adjacent metal layers in the wound laminate. A common coating method is described in U.S. Patent No. 2,796,364 described by Schiff, which discloses a method of forming a magnesium oxide layer as an insulating layer on the surface of a metal strip. As described in the case, methylmagnesium is dissolved in an organic solution, and the solution is applied to the surface of the metal strip. The metal band is then heated to a high temperature to form a strongly bonded magnesium oxide on the surface of the metal band. The metal strip can be wound to form a magnetic core. Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs -------------- LI (Please read the notes on the back before filling this page) There are several disadvantages to the treatment of methyl hydrazone. First, methylmagnesium must be applied to the metal strip before it is wound into a core. After the metal strip is unraveled, the strip is immersed in a groove to form a coating, the coating is heated and cured, and the strip is wound around to form a core, making processing slow and noble. Therefore, methylmagnesium is not suitable for providing low-frequency, high-volume insulation to the plutonium iron core. Second, it is very p. 3 This paper is in accordance with Chinese National Standards (CNS) A4 regulations (21OX 297) 508595 A7 B7 5. Description of the invention (It is difficult to control the thickness of the obtained magnesium oxide insulation layer. Some magnetic core applications have problems, such as pulsed iron cores, * which have very high performance requirements that are difficult to accomplish: unless the applied methylfluorene layer is very thin. Forming a thin methylfluorene coating requires special treatment that is fast and difficult to control. For For these applications, the application of methylmagnesium is particularly expensive, and the core obtained is fragile. Furthermore, in applications that can accept thick insulating layers, when excessive non-conductive insulating materials are used, the magnetic core space of Angstrom is occupied. This reduces the space factor of the laminate, so that the percentage of the core occupied by the magnetic material decreases with the efficiency of the core. Finally, because methylmagnesium must be coated before the tempering step, it is also due to the coating and 2 magnetic Stresses are established between materials and interfere with the alignment of magnetic domains during tempering. Methyl magnesium treatment cannot be used to form some types of iron core insulation at the same time. South temperature systems need to be properly cured on metal strips Methylmagnesium. Typically, the methylmagnesium coating must be heated to at least 843 ° C (1 550T) or higher to form a magnesium oxide film that firmly adheres to the metal strip. However, for example, non- Some soft magnetic materials of crystalline metal alloys cannot be heated to a temperature higher than 449t (840T) without destroying their desired magnetic properties. When methylmagnesium is used as an insulating material for these metal alloys, it is Heat to a lower temperature and the resulting magnesium oxide is only loosely bonded to the metal strip. As a result, these types of cores cannot be cut to form C or E cores, because the strong cutting action will separate the loosely bonded insulating coatings. The cutting core, for example, the endless belt may be formed of an amorphous metal alloy coated with a methylmagnesium treatment. Furthermore, the inventors know that another method can be used to form a C or E magnetic core of an amorphous metal alloy. The process involves A thin non-continuous magnesium oxide coating was formed on the tape before winding, because the coating was not continuous and was caused in the iron core on page 4. This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm) ( (Please read the notes on the back before filling this page) Order: Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs 508595 Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs A7 B7 5. Description of the invention () High power consumption at high frequencies Therefore, there is a need for improved methods to form thin dielectric insulation on soft magnetic metal strips used as magnetic cores. At the same time, there is also a need for insulation to allow #crystalline metal cores to be processed to form high-frequency c and E iron core. Purpose and summary: The present invention advantageously overcomes the shortcomings of the prior art by providing a process to form an insulating layer between the core and the metal layers of a magnetic core after the core is wound. This process can be used to provide Insulation of various metals and metal alloys used as magnetic cores, including amorphous metal alloys. The insulating material formed by the treatment of the present invention is fixedly bonded to the surface of the metal strip forming the core, and the core added with this insulating material can be cut to form a c or E core, or other known to those skilled in the art. Cutting iron core. Result 'For the first time, the C and E cores can be completed under an amorphous metal alloy. The alloy is protected by an insulating film and is suitable for high frequency applications. In one aspect of the present invention, there is a method for providing dielectric insulation between adjacent metal layers of a laminated magnetic component. The method comprises a first step of oxidizing a laminated magnetic component, wherein the component is a layer made of a majority of iron. Oxidation produces a coating containing a mixture of iron oxides. The resulting magnetic module has a resistivity greater than about 500 ohm-cm. The oxidation step may include exposing a plurality of layers to an aerobic vapor at a temperature of at least about 260 ° C (550 ° F). More preferably, the layers can be heated to a temperature between about 260 ° C and 4 2 7 C (50 ° F to 800 ° T). When the layers are amorphous metal alloys, it is preferred that the layers be heated between about 3 54 ° C and 427 ° C (670 ° F and 800 ° F). Where page 5 of this paper applies to Chinese countries Standard (CNS) A4 specification (210 X 297 mm) (Please read the precautions on the back before filling out this page) Installed by the Intellectual Property Bureau of the Ministry of Economic Affairs and printed by the Consumer Cooperatives 508595 A7 -_________ V. Description of Invention The ring core is preferably from about 354 ° C to 379 ° C (670 ° F to 715 卞). In a preferred embodiment of the method, the oxide laminated magnetic component exhibits a reduction of at least 15. /. The power loss' is at an operating frequency of 10-20kHz, compared to magnetic components before exposure to steam and air. In another aspect of the present invention, there is a method of manufacturing a dielectrically insulated soft magnetic component. The method includes a first step of winding an iron-containing amorphous metal alloy ribbon into a multilayer core. Then, the iron core is heated in water and oxygen to oxidize iron in the amorphous metal alloy strip to form a coating including iron oxide. The coating is at least about 0.0 3 microns thick. In another aspect of the present invention, a soft magnetic assembly including an elongated amorphous metal strip is provided. The band is at least about 40% iron. The belt has a first side and a second side. The first side has a small protrusion and the second side is substantially smooth. The tape is wound to form a laminate so that the protrusions on the first side contact the smooth second surface. An iron oxide-containing coating substantially covers the smooth second surface and at least a portion of the protrusion that contacts the smooth second surface. The coating preferably has a thickness of 0.03 microns or more. In some embodiments, more than 75% of the coating contains iron (II) oxide and iron (IV) oxide (ie, Fe203 ~ FeO, which is called magnetite and iron (II)) . Preferably, the coated soft magnetic component has a resistivity of more than 500 ohm-cm, more preferably more than 1000 ohm-cm, and most preferably more than 10,000 ohm-cm. In one aspect of the invention, a dielectric insulating coating is provided between the contact points of adjacent metal layers of a soft magnetic component. The coating mainly contains a sufficient amount of iron (melon) oxide to reduce the power loss in the component by at least 15%. Preferably, the dielectric insulation coating is a sufficient amount to reduce the power loss in the module * Page 6 The paper size of the mound is applicable to the Chinese National Standard (CNS) A4 specification (210 X 297 mm) Wei (Please read the back first (Notes for filling in this page)

508595 Printed by A7 B7, Consumer Cooperative of Intellectual Property Bureau of the Ministry of Economic Affairs 5. Description of the invention (at least 30%, preferably at least 45%. Purpose and summary of the invention: In another aspect of the present invention, a soft magnetic component is provided. There is an insulating coating material between adjacent metal layers of the component, the coating substantially comprises an oxide of iron, and the component has a resistivity of at least 1000 ohm-cm. In another aspect of the invention, wherein There is a method of forming an insulating coating on the surface of an amorphous metal alloy strip. The method includes providing an amorphous metal alloy strip in which the percentage of iron exceeds any other percentage of the element in the alloy. Then, The belt is heated to the tempering temperature of the alloy. The belt is then exposed to aerobic steam to form bells, _, ... // τ to form iron (oxide coating on most of the belts). Alternatively, before heating the strip to a tempering temperature, the strip may be wound into a core. In another aspect of the present invention, a magnet 0-shaped core is provided. * The core has a majority of amorphous metal alloy strips to form a core. Laminated, its shape is semi-circular 'semi-elliptical or semi-rectangular. Metal oxide insulation coating is between adjacent bands in the laminate. The oxide is formed by the oxidation of iron. At an operating frequency of 10 k Η z or higher, the insulation coating reduces the recognized power loss by at least 15%. The diagram is briefly explained: Figure 1 is a perspective view of a toroidal magnetic core. Figure 2 is the first Cross section of the magnetic core shown in the figure. Page 7 This paper size is applicable to China National Standard (CNS) A4 (210 X 297 mm). (Please read the precautions on the back before filling this page)

A7

V. Description of the Invention () Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs When the Λ% J picture is a cross-sectional view of a non-Yellow metal band wound before forming the insulating material of the present invention. Fig. 4 is a sectional view of the amorphous metal laminate of Fig. 3, which shows the oxide insulating material of the present invention. Figure 5 is a comparison of the improved performance of a coating using steam generated from feed water having an alkaline pH. Fig. 6 is a diagram of a pulse tester device for performing a ring pulse test. Figure 7 is a spectrum of pores of an aluminum silicate matrix suitable to provide a migration matrix for iron oxide. Figure 8 is an adsorption / removal isotherm of an aluminum silicate matrix suitable to provide a migration matrix for iron oxide. Figure 9 is a graph of core flux versus drive levels for an uncoated impregnated core. Figure 10 is a plot of permeability versus power (watts / watt) for an uncoated impregnated core. Fig. 11 is a flux-to-drive level diagram of a core for a coated impregnated core. Figure 12 is a plot of permeability versus power (watts / pounds) for coated impregnated cores. Figure 13 shows the permeability versus tempering temperature of an uncoated core. Figure 14 shows the permeability versus tempering temperature of the coated core. Figure 15 shows the flux vs. drive level of a 0.01-pound iron core processed at 690 and 725 ° C under roving conditions. Figure 16 shows the core flux vs. drive level for the uncoated and unimpregnated core. Page 8 This paper is sized for China National Standard (CNS) A4 (210 X 297 mm) (Please read the back (Please fill in this page again)

508595 A7 B7 V. Description of the invention (1) Figure 17 shows the magnetic permeability versus power dissipation (watts / pounds) of uncoated and unimpregnated iron cores. Figure 18 shows the core flux versus drive level for a coated unimpregnated core. Figure 19 is a plot of permeability versus power (watts / pounds) for a coated, unimpregnated core. Figure 20 is a graph of apparent permeability versus indicator clearance expressed in centimeters for the return analysis of the data in Table 12. Figures 21 and 22 are data graphs of power loss improvement provided by the application of the present invention at a temperature range of approximately 6800 to 800 ° C. < Please read the notes on the back before filling in this page) Drawing number comparison description: 10 Magnetic core 20 Metal belt 30 Mandrel 40 Insulating material 120 Belt 121 Smooth surface 122 Coarse sugar surface 130 Clearance 150 Dot detailing-Ministry of Economic Affairs Printed by the Intellectual Property Bureau's Consumer Cooperatives, which can be part of the pre-existing chemical oxygen alloy is Jin Ran Yu Guan Zhiming's hair ferromagnetic forming,-, the core and the core are wrapped around the core by the magnetic core iron ring Yi Keying but the technique described by those who are based on the nature of β $ learning. The% G is familiar with it, and it is issued as in this example. 〇 Xie Xin teaches that the magnetic shape is based on the inch, the size and the shape of the shape. There is a guide to use. The Chinese paper standard (CNS) A4 (210 X 297 mm) is applicable to the 9th paper size of the clarifiable paper. 508595 A7 B7 5. Description of the invention (C magnet core, E magnet, and others are known to those skilled in the art Laminated magnetic components. Furthermore, the present invention can be applied to magnetic components including laminated layers, 'the laminated layers can be unwound, for example, to form a magnetic laminated layer component by stacking continuous layers. Refer to FIG. 1, which shows The schematic diagram of the winding ring magnetic core ι0 added to the present invention is shown. The magnetic core 10 is formed by winding a thin metal strip 20 around a mandrel 30 to form a laminated layer. The mandrel 30 is only a hard substrate, and Surrounded by a band, such as an elongated metal bar or rod. The mandrel 30 is removed in subsequent core processing. It is not part of the final magnetic core 10. The mandrel 3 can have various sizes and shapes, such as circular , Rectangle, square, etc., which It can be selected to form iron cores with different shapes and sizes. The metal strip 20 is wound around the mandrel 30 for a sufficient number of turns to form a multilayer stack of desired thickness. For the purpose of the present invention, the metal strip 20 can It is wound to form a core of size, size and weight available on the market. After the winding is completed, the magnetic core 10 can be tempered to optimize its performance as known to those skilled in the art. Metal belt 20 series It is a soft magnetic metal or an alloy with iron as the main metal. The metal strip 20 is preferably thin and has a thickness ranging from about 0.01 mm to 0.3 mm. The metal strip 20 may have a width of 0.1 to about 25 cm. For high frequency power loss, the insulating material 40 is provided between adjacent layers of the metal strip 20. As shown in Figure 2, the magnetic core 10 has a coating of the insulating material 40 between the layers of the metal strip 20. The insulating material 40 is Formed on at least a portion of the metal strip 20, which is in contact with adjacent metal layers, and therefore 'resistance to the amount of current between adjacent metal layers. In some embodiments, the metal strip on page 10 of this paper applies Chinese national standard (CNS) A4 specification (210 X 297 mm) (Please read the notes on the back before filling out this page) Order · Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 508595 A7 _ — _ B7__ V. Description of the invention () ( Please read the notes on the back before filling in this page} 20 can be an amorphous metal alloy, preferably iron is the transition metal and the main metal is 'with the TM-M formula' where TM is at least 80/0 iron, The remaining 20% of 〇 or criminal or its mixture 'contains M, where M is selected from the group consisting of B, c, Si, P or Ai or a mixture thereof. In other embodiments, the metal strip 20 may be finely crystalline material. Preferably, the present invention provides a special treatment which can be used to form the insulating material 40 between adjacent metal layers of the metal τ 20, after the metal strip 20 is wound around the bowl core 10. Therefore, the time consumption of the prior art and the expensive coating process can be avoided. Furthermore, the unique insulating material 40 of the present invention is thin and fixedly adhered to the metal tape 20. Therefore, when the insulating material 40 is formed on a magnetic core made of an amorphous metal alloy, the core can be cut to form a soft magnetic component that could not be previously completed, such as the c and £ cores of the amorphous metal alloy.丨 Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs, and T 'Insulating material 40 is formed by oxidizing the metal strip 20 to form a natural metal oxide or alloy metal of the metal to become a very thin coating on the metal On the surface of the band 20. The natural metal oxides of most metals used to form iron cores have a relatively high resistivity and are particularly suitable as insulation between adjacent metal layers. Because most metals and metals in the alloy that can form the metal strip 20 can be oxidized to form a metal oxide, which has a sufficient electrical impedance to form a suitable insulating material. 40 'The present invention is generally applicable to today's use Soft magnetic core material. Table 1 shows representative examples of metals and metal alloys that can be used in the present invention, and the relevant chemical composition of insulating materials that can be created by oxidized metals < Renjin. Page 11 This paper size applies Chinese National Standard (CNS) A4 specification (210 X 297 mm) 508595 A7B7 V. Description of the invention () Table 1 _ Part of the detailed elements of soft magnetic materials Metal alloy composition Trade name Natural metal oxide insulation Material F e, Ni 40% Fe, 38% Ni, 18% B, 4% Mo METGLAS Alloy2828MB FeO, Fe203, Fes 04Fe, B 81% Fe, 13.5% B, 3% Si, 2% C METGLAS Alloy2605SC FeO, Fe203, Fe3 〇4 F e, C ο, Ni T (70-80%) 'M (30-20%) Amorphous and fine crystalline FeO, Fe203, Fe 3 0 4 Fe, B 70% Fe, 9% B, 3% Nb, 2% Cu, Mo, Co, Si Fine crystalline FeO, Fe203, Fes 04Fe, Co 67% Fe, 18% Co, 14% B, 1% Si METGLAS Alloy 2605CO FeO, Fe2〇3, F e 3 0 4 Fe, Co 49% Fe, 49% Co, 2% V SUPERMENDUR FeO, Fe2 03, F e 3 0 4 (Please read the notes on the back before filling (This page) Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs T = Fe, Co, Ni M = B, C, Si, P, A1, where iron is the main metal in the alloy, for example, in METGLAS alloy 2005SA1, the insulation material system Mainly formed from iron oxide (Fe2〇3) The others are most iron oxides (II-III). For example, for 690T steam and air page 12 * This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm) Printed by the Employees' Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 508595 Α7 _Β7 V. Description of the invention ( ) Gas treatment of an iron core for 6 hours. The Raman spectrum shows that the insulation layer is composed of about 80-90% Fe2O3 and magnetic core 10-1 ::>% Fe304 (ie, iron (II-III) oxide), with a small amount FeO composition. This layer has a 0.15 micron thick iron oxide mix. It can be exemplified by those skilled in the art that the aforementioned representative alloys and metals are examples, and the teachings of the present invention can be applied to iron-based alloys composed of components other than those described above. For example, the present invention can be easily applied to an iron-based alloy in which only a percentage of the alloy is changed, or an alloy of a new metal or an element is introduced without change to oxidize to form an insulating iron oxide. The insulating material 40 should be formed to be sufficiently thick and sufficiently resistive to effectively insulate the excess layers of the metal strip 20 and the current between the layers. If the insulating material 40 is too thick, the magnetic core 10 will contain an excessive amount of non-conductive insulating material, and the magnetic core 10 will have a low space factor. The percentage of the magnetic core 1 occupied by the magnetic material is quite low, reducing the core efficiency . Preferably, the insulating material 40 is formed to have a thickness of 0.01 to 5 m, more preferably 0.03 to 2 m, and most preferably 0.03 to 0.5 m. Of course, it should be understood by those skilled in the art that other thicknesses of the insulating material 40 can be provided by changing the processing conditions as described below. For example, when the insulating material 40 is mainly formed of a metal oxide having a relatively high resistivity, a thin film can be used to increase the space factor and core efficiency. Furthermore, for some applications, a greater amount of insulating material 40 may be desired between adjacent metal layers, such as for very high frequency and pulsed power applications. Preferably, the insulating material 40 is sufficiently thin so that the resulting core has a space factor of at least 70%, preferably 80% and most preferably 85% or more. The resistance added to the laminated layer of the present invention is the waveform of insulating material 40. Page 13 This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm) (Please read the precautions on the back before filling this page )

Printed by the Consumers ’Cooperative of Intellectual Property Bureau of the Ministry of Economic Affairs A7 _—... _ ^ 15. Explanation of the invention () Factor multiplied by the resistivity of the metal oxide as a function of the absolute e, '豕 何 豕0 Edge resistance created by metallic materials. For a τ 10,000 digit application, it is preferred that the magnetic core 10 has an effective resistivity of 500 ohm-cm and is more preferably 1000 ohm-cm ', more preferably 10,000 ohm-cm. However, it should be understood by those skilled in the art that the present invention can be easily applied to create an insulating material 40 having a laminate having a laminate resistance greater than or less than the stated value, by changing the processing conditions described below. The magnetic buildup layer formed using the present invention can be supported by each layer of at least about 2 to 10 volt buildup layers. Generally, the insulating material 40 is formed by the oxidation of iron controlled in the metal strip 20. The current preferred method of oxidation is to expose the magnetic core 10 to the high temperature of air (about 20% oxygen). Steam and air diffuse into the wound core 10 and come into contact with the surface of the heated layer of the metal strip 20, which causes accelerated oxidation of the surface of the metal strip 20 to form a thin metal oxide coating or layer on the surface of the metal strip 20. When an alloyed metal reacts with oxygen, steam and heat accelerate the electron mobility to form iron oxide. Processing conditions can be varied to further accelerate electron migration during some or all reactions, such as introducing catalysts detailed below, or increasing temperature to reduce steam particle size. Furthermore, as is known to those skilled in the art, different processing conditions that accelerate electron migration between metals and oxygen to form natural metal oxides can replace or supplement the steam / air combination. These other processing conditions may include exposing the laminate to high concentrations of highly reactive oxidizing molecules, such as ozone ' nitrogen oxides, and other highly reactive oxides of nitrogen. I would like that if these highly reactive molecules are introduced in a controlled manner in conjunction with the treatment, the reaction rate will be accelerated to form insulating metal oxides. Page 14 This paper size is in accordance with China National Standard (CNS) A4 (210 X 297) (Please read the note on the back first 顼 江 窎 窎 本 贡 >

508595 Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs A7 B7 V. Description of Invention () Furthermore, for an application, I want to form metal sulfides as an insulating material. To accomplish this, hydrogen sulfide (HJ) can be substituted for water 'in steam to form natural metal sulfides as the insulating material of the present invention. Other similar oxygen and sulfur, such as selenium, can be used as electron acceptors to form insulating compounds between adjacent metal layers. You can quickly understand the changes in processing conditions or materials that help Yuan Cheng and accelerate the penetration of steam or 2 gas between all layers of the heated component, such as iron core 10 will result in faster processing time and more uniform coating Or insulating material 40 on the belt 20. The inventors of the present case have chosen a surface interface shape of 20 that can be selected to optimize the diffusion or penetration of steam and air between layers. Referring to FIG. 3, there is shown an enlarged sectional view of a wound core 100 made of a soft magnetic material. The iron core 100 may be made of any one of the metals or alloys disclosed in Table 1, and variations thereof. The iron core 100 has multiple layers of metal strips 120, of which four 120a-d are depicted in Figure 3. Adjacent metal layers 120a-d are provided with an insulating material therebetween, so that a conductive current flows through the contact point. As shown in FIG. 3, the belt 1 20 has a relatively smooth surface 1 2 1 and a rougher surface 122. The rougher surface 122 is characterized by protrusions or small dots 150 which protrude from the surface by a small distance compared to the thickness of the layers 120a-d at the scattered points on the surface of the metal strip 122. When the belt 122 is wound to form a laminate, as shown in FIG. 3, the small point 150 is in contact with the smooth surface 121, thereby establishing a current flow path between the adjacent metal layers 120a-d. 〆The small gap 130 is established between adjacent metal layers, and it is defined by the distance of the small point 150 protruding from the surface. Preferably, the gap 130 provides a path for the penetration of steam or air into the winding core 100 in the process of the present invention. Page 15 This paper is applicable to the Chinese National Standard (CNS) A4 specification ( 210 X 297 mm) (Please read the note on the back? Matters before filling out this page}

) ⑽ 595 A7 B7

5. Description of the invention (Department. Metal belts with the above-mentioned gaps and small dots can be made of, for example, amorphous metal alloys sold by Wei, called thin dishes. For METGLAS belts, all belong to the > τ Fi main and metal. The morphology of the surface interface of τ 120 is a processed product used to build "T 120" processing conditions. The Metglas belt is formed by spraying a molten metal alloy to the surface of a rotating drum with liquid cooling. The molten metal is Cool at a rate of about 1 GG () sail or faster per second .: Gold solidifies before the atoms have a chance to separate or crystallize. The resulting solid metal alloy: has a non-printed glass-like atomic structure. The surface of the solid belt contacting the drum is more Thick, because of the small defects introduced on the drum surface, resulting in a small point of 150. 乂 Refer to Figure 4 ', which does not show a cross-sectional view of the laminate of Figure 3, which has been provided with the insulating material of the present invention. As shown in Figure 4: The metal oxide material containing the insulating material 14G has been formed between the adjacent layers 120a. The insulating material 14o is formed on a relatively smooth surface with a rough surface 122 1, especially covering Got a little 15Q. The edge 4i40 system is located between the metal contacts of the adjacent metal layer 120ad, and the previous flow path system is interrupted. As a result, the lamination shows the preferred processing conditions of the present invention for the current path to oxidize the metal to form a metal oxide insulation material system. Depends on the core metal and the desired magnetic properties. For example, when Fe / Si / C / B amorphous metal alloys are processed, it is preferable to heat the core to a temperature of from about 26 (TC to 427 ° C ( 500T to 800 卞), more preferably 354 C to 365 C (670 F to 690 F) 'g, and apply a long magnetic field. When flat ring characteristics are desired, heating is preferably greater than about 399t (75 ° C) ) To about 416 ° C (780 ° F). When the characteristics of the ring are desired, the heating is preferably about ⑺ page 16 This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297) I -------------- * ΙΓ (Please read the notes on the back before filling this page) Order ·

Printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs 508595 A7 B7 V. Description of Invention () ° C and 388 ° C (71 ° F to 730 ° F). For amorphous metal alloys, good results have been achieved by heating the core to its tempering temperature and simultaneously forming metal oxides during tempering. For most amorphous metal alloys, the tempering temperature is 354. (: To 365 (67 ° to 690 ° F), but several of this alloy have tempering temperatures outside this range. The tempering temperature of metal alloy strips as magnetic cores is already known to those skilled in the art. For example, the tempering conditions used for amorphous metal alloy METGLAS have been reported in Alai Signal and Hannover Advanced Materials Technology Bulletin. I have observed that the processing system for forming insulating materials is more effective. If the winding core is wound in a cycle If the furnace is used for treatment, a furnace suitable for this treatment is a model of AGC7-1406G from Blue Island, Illinois, USA. The air / steam mixture is circulated in the furnace to maintain the uniform temperature of the furnace, so that air is brought into the furnace to establish an oxidation reaction. After this treatment is completed, the furnace is cooled down. The iron core should be exposed to steam for a long enough time to form 40 layers of insulating material for iron core applications. I have found that it can be used for a period of 0.5 to 12 hours or more Good results have been observed when the exposure time is from 1 to 6 hours, preferably from 2 to 6 hours, and most preferably from 4 to 6 hours. The steam pressure should be sufficient to cause steam to penetrate into the laminated components. The current steam pressure is about 0.1 to 2.5 psi, preferably 1 to 2 psi, which is sufficient for this purpose. However, other steam pressures can also be used and are known to those skilled in the art. For example, the steam waste force range is given by 0 · 1 to 1 000 s or more can also be used. Furthermore, the steam flow introduced into the thorium must be sufficient to allow the coating to form. Preferably, the flow rate is at least 0.2 2 plus sho / hour Furnace space per cubic sigh, more preferably at least 0 · 25 5 gallons per hour without cubic per cubic meter, the most up to page 17 This paper size applies Chinese National Standard (CNS) A4 (210 X 297 mm)- ------------- · ΙΓ (Read the notes on the back before filling in this page before Qing) · Bu Xian 'Printed by the Intellectual Property Bureau Employee Cooperatives of the Ministry of Economic Affairs 508595 Employee Consumption of the Intellectual Property Bureau of the Ministry of Economic Affairs Cooperative printed A7 B7 V. Description of the invention () Less 0.26 plus life / hour per cubic sigh. A flow restrictor that can be used to control the flow of steam ingress includes a circle with a diameter ranging from about 1/18 inch to 5/8 leaves Hole-shaped socket. The enhanced growth and thickness of the coating on the metal strip are observed When steam is added based [Fex〇y] + z cation 'of the formulas herein wherein x, y, 2 factor is 1 $) $ 2,1 ^) ^ 3 ^ 3, $ 2. [1 ^ (^ The iron part of the broad cation is considered to be very active to complete the oxidation on most iron surfaces of MET gl AS 2 6 0 5 SA 1 ', and other iron-rich amorphous alloys and other metals can be used. In the present invention, due to the consideration of the oxidation state, the iron cation starts the required electrochemical reaction and is easily coupled to the iron bond. It may also be partially dissolved in the steam Fe: 203 is limited to the growth of the coating oxide on On the surface of metal, to increase its thickness and insulation characteristics. A suitable source of iron cations can be simply iron oxide residues in iron boilers used to generate steam. A preferred source is to surround [FexOy] + z cations as a migration matrix 'Iron cations with a known concentration are placed in the steam path. The use of this migration matrix improves the uniformity in the coating process, resulting in a more uniform magnetic performance for amorphous metal alloys and amorphous materials. Preferably, the Fe2O3 (source of [FexOy] + z cations) added to the matrix is packaged, that is, absorbed, the matrix has a high surface area and surface characteristics, and ^ completes the release of [Fex〇y] + z cations And possibly Fe 203 molecules enter the steam. The matrix should have a high surface area and be distributed in a multi-model pore to dilute and cooperate with strong decomposition characteristics. The inventors of the present case have found that a suitable matrix can be obtained by immersing aluminum silicate in a diluted chlorine Iron solution (which has been clarified with HC1), mixed with MH4〇H, and heated to absorb the generated oxidation. Page 18 This paper applies China National Standard (CNS) A4 (210 X 297 mm). (Please read the notes on the back before filling this page)

508595 A7 B7 V. Description of the invention () (Please read the notes on the back before filling this page) Iron to form. A substrate with 10% w / w iron should be supplied with sufficient iron oxide cations. Such a matrix system is commercially available from Amorp h i c 〇, Hessipyl, California. Compared with the iron core which is not exposed to the iron oxide cations from the aluminum silicate matrix, the reduction in power loss for the core using the silicon aluminum matrix completed by the treatment of this case is typically not less than 30%, and for METGLAS2606SA1 it will be 50 %, This case has improved the uniformity compared with the efficiency of the boiler plate or hard water. Referring to Figures 7 and 8, there is shown an absorption and decomposition isotherm distribution and spectrum diagram of a suitable aluminum silicate that can be used as a Fe203 matrix. Figure 7 depicts a material with a high internal pore surface area (exceeding 200 meters squared per gram) and a wide pore size distribution ranging from 20 to 1000 Angstroms. Figure 8 depicts a near-ideal isotherm for the slow release of [FexOy] + z cations into the jet steam for practical time periods for many consecutive batches of coatings. In short, aluminum silicate completes an acceptable time release matrix for [FexOy] + z ions. The Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs printed a combination of aluminum silicates shown in Figures 7 and 8 showing a combination of high surface area and near-ideal decomposition characteristics to create a matrix that releases [FexOy] + z cations and Fe2. 3 molecules become a low-pressure steam source. "Doped" steam is sequentially transmitted between the [Fex〇y; | + z cations and Fe203 molecules between the cores of the impact zone. The deposition of Fe203 and iron ion cations enhances the oxidation of iron in the metal alloy, thereby Complete effective insulation coating. Approximately 20 cubic inches of silicic acid, iron-copper matrix has a useful life of at least 20-44 hours per production process, that is, 4-8 hours per cubic inch of ferric aluminum silicate. The matrix can supply 1 5 0 to 2OOppm of iron oxide / iron oxide ions into the steam entering the chamber and produce an acceptable coating. Page 19 This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm)

V. Description of the invention () The performance data of the iron core formed by using the ferrous aluminum silicate matrix of Figs. 7 and 8 is shown in Table 2 below. The data shown in Tables 2 and 9 were created using a steam source of 5 to 10 psi, a tank with a diameter of 0125 inches and a volume of 20 cubic inches, and an iron silicate between the steam source and the coating chamber furnace. The vapor pressure in the coating chamber furnace is typically from 0.5 to 2 pSi, and the coating is generated by exposing to steam for 4 hours at 690T to 700 Torr. Table 2--6 i% March core weight produced by Meglas 2605SAl versus power loss core weight (lbs.) Low power loss (W / lb) Medium power loss (W / 碡) High limit (W / 碡) • 05 9.8 11.9 14.0 • 08 10.2 10.5 10.7 • 22 9.0 丨 9.0 9.0 • 31 9.6 10.5 11.5 .36 10.8 12.1 13.4 .41 8.1 8.8 9.6 • 43 9.3 12.7 ----- 16.1 .435 16.2 18.7 21.1 • 58 9.3 11.9 ----- -14.5 • 70 14.1 14.6 15.1 .705 9.3 11.5 13.7 • 77 10.6 12.6 14.6 .83 10.2 15.3 ---- 20.3 1.06 1.3 16.1 ----- 18.9 2.41 13.9 13.9 13.9 Page 20 Intellectual Property Bureau Staff Consumer Cooperatives, Ministry of Economic Affairs Printed (Please read the precautions on the back before filling in this page) This paper size applies to China National Standard (CNS) A4 (210 X 297 mm) 508595 A7 B7 V. Description of the invention (2.42 10.3 12.5 14.8 4.50 9.1 10.3 11.4 5.2 8.5 9.2 10.0 5.73 1.5 1.5 1.5 5.97 11.2 15.4 19.5 6.37 7.5 7.9 8.3 6.57 11.4 14.3 17.1 8.32 10.1 10.2 10.2 8.6 9.5 9.5 9.5 9.5 The power was measured at 20KHz and 0.2 Tesla. The average core weight was calculated in watts per pound ( Please read the notes on the back before filling (Page) Preferably, the magnetic core is tempered before or at the time of the oxidation treatment, which is used to form an insulating material on the surface of the metal strip. As known to those skilled in the art, tempering is reduced in the magnetic core. The magnetic discontinuity can give the magnetic core the desired magnetic properties. The appearance of a full-layer insulating metal oxide between the core layers interferes with the tempering process by the establishment of stress. This is because the core is wound and then tempered. At or after, the insulating material is formed to avoid the processing of the magnetic core. Because the process of the present invention produces metal oxide insulating materials at or below the tempering temperature, this preferred sequence can be used for most types of magnetic cores. An example of achieving a good structure is to temper an amorphous metal alloy core (containing iron as the main metal) in a magnetic field at an air temperature of about 365 to align the magnetic domains in the core. The core is exposed to steam Before the iron oxide insulating layer is formed, the furnace temperature is then lowered to 305 to 329t (58 ° page 21 order.… Line _ Printed by the Ministry of Economic Affairs Intellectual Property Bureau Staff Consumer Cooperatives 508595 A7 B7 5. Description of the invention () to 625 F). Even though the tempering system is completed in the air to be higher than the insulating layer formed by the process of the present invention, there is no U metal oxide on the surface of the tape to provide dielectric insulation between the layers. Another example that produces particularly good results is when the iron core is tempered. "Rhenium steam and 2-gas treatment of amorphous metal alloy cores, with iron as the main metal. In other words, the formation and tempering of an insulating iron oxide coating Simultaneous. The tempering temperature of the amorphous metal alloy will specify the precise temperature of the treatment, as described above. The coating of the present invention simultaneously achieves excellent performance by introducing or releasing mechanical stress. As is familiar to those skilled in the art It is known that the power loss in the soft magnetic core has two components. The first component is the eddy current, which is caused by the change in the magnetic flux of the voltage introduced into the substrate layer. The eddy current loss is directly related to the operating frequency of the induction coil, and JL It is a small role in low operating frequency of 4⑽Ηζ or lower, especially in amorphous and fine crystalline materials. Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs (please read the precautions on the back before filling in this (Page) The power loss of the wire < The second component is caused by the hysteresis effect, which is the amount of energy loss when the magnetic material repeats a magnetization cycle. Put on the magnetic material The stress can increase the hysteresis loss by affecting the magnetic domain activity formed in the magnetic material. In particular, when applied to large magnetization restrictions, such as amorphous metal alloys, the hysteresis cycle of the material is particularly undesirable. When applying metal band tempering, the coating of the present invention allows for reduced stress on the underlying metal band. The softness of the iron oxide of our coatings constitutes this effect. Because the coating can move at typical tempering temperatures, it is The stress on the metal strip is reduced because the coating, when tempered, releases stress as a lubricant on the metal strip and improves its performance. For example, under low frequency operating conditions, when the eddy current loss is small Page 22 508595 A7 B7 V. Description of the invention () The simultaneous tempered coated core of the present invention has improved performance compared to the uncoated core. See Table 3 below. This improved performance will not be expected to be changed by the dielectric insulation of adjacent metal layers. , And can partially establish the stress on the metal strip that reduces the hysteresis loss. Furthermore, the effect of the stress released on the lower metal strip can be broken by the microscope to the line of Tu Guangzhong. In addition, the coating of the present invention does not introduce any unwanted compressive stress on the magnetic core due to thermal expansion. I know that the expansion coefficients of METGLAS 2605SA1 and 2605SC are 7.6 and 5.9 ppm each. C. General tradition Materials used as insulation such as manganese oxide and MYLAR have an expansion coefficient of 8 and insulation materials of 40-9Oppm per C. Because the expansion coefficient of insulation exceeds that of metal, the use of MgO or MYLAR as insulation has introduced compression in the operating temperature range. I believe that the stress of the core increases the power loss factor by two. However, 'the coating of the present invention does not introduce compressive stress' and greatly improves the performance. Table 3 below is designed by processing METGLAS 2605SA1 and 2605 SC to eliminate Comparison of data on cores formed by stress. In particular, the coating is formed by heating and winding the core to 670-690 ° F for four hours while exposing the core to steam at a pressure of 0.1 to 0.5 psi. The data of these cores are compared with those formed by manganese methyl treatment (MgO). The results are shown in Table 3, and the coated cores 2 and 4 for the amorphous material reduced the loss by 50% compared to the standard manganese methyl coated cores 1 and 3. Page 23 This paper size is in accordance with Chinese National Standard (CNS) A4 (210 ^ 297 mm) (Please read the precautions on the back before filling out this page) Printed by the Employees ’Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs

508595 A7 B7 V. Description of the invention ()

Table 3: METGLAS2605SA1 & 2605SC: 5.25 "UDX4.0 " IDX2 ,, SW # Material processing conditions core kW start ampere set ampere pulse Jim3 1 2605SA1, standard (MgO) 95.3 25 42 810 2 2605SA1, coating, zero stress △ B = 2.BT, 2 # s 57.7 10 20 490 3 2605SC, standard (MgO) Z \ B = 2.6T, 2 / 2S 102 25 40 867 4 2605SC, coating, zero stress △ B = 3.05T, 2 / zs 61 10 20 518 Conditions: Apply 5.35-5.8 kV to the core and use 6 turns, lOpps, and 2 # second pulse width, flux 2.8-3.05T (Please read the precautions on the back before filling this page)

Processing enhancements to change the magnetic properties The processing temperature at which the coating can occur can be adjusted to adjust the basic magnetic properties of the resulting core. For amorphous metal alloys such as METGLAS 2605SA1, exposure to steam to temperatures from about 3 88 ° C (730 ° F) to 427t (800 ° F) tends to produce round and flat ring characteristics. When a longitudinal magnetic field is applied when the coating is formed, temperatures below 37 ° C (71.5 ° F) tend to produce a square ring characteristic. Temperatures between 379 ° C to 3 88 ° C (715 to 730 ° F) tend to produce iron cores with toroidal magnetic properties. For example, if you want a flat ring feature for a toroid, the application can be used with a gap to limit the effective magnetic permeability. However, gaps require additional processing steps, which typically result in considerable power dissipation compared to loops without gaps. Equivalent flat ring characteristics can replace the example of lower power dissipation (because there is no gap) and the potential upper line is easier to manufacture (because there is no need to cut a room) Page 24 This paper applies Chinese National Standard (CNS) A4 Specifications (210 X 297 mm) Printed by the Consumers ’Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs, printed by the Employees’ Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs. When a flat hysteresis ring is generated, this is more difficult. The reason is that the transverse magnetic field is perpendicular to the circumferential direction) 'Therefore, a special magnetic field generator is needed. Magnetic field generation: The device is typically a multi-turn solenoid with a current carrying current, which is built by a large wire enclosed in a furnace or an electric field placed outside a large C-shaped iron core electromagnet with a gap. The gap is passed through an appropriately oriented core (heated channel. In the following example, the furnace must be specially designed for rod field tempering and is particularly limited by very specific core sizes. Solenoid shells are usually very limited. The amount of elements placed horizontally 'is susceptible to excessive processing changes. However, when the present invention is matched with an appropriate tempering temperature, a flat hysteresis ring system is easier to form. More specifically, when METGLAS 2605A1 is heated to 715 ° F. When the vertical magnetic field is used to locate magnetic domains for hours or less, the general square ring characteristics are always obtained. This has been verified in production and applied to iron cores from 丨 pounds to over 40 pounds. At temperatures close to 715T-73 ° C or higher There is no sharp change in the transition between the square 'round and flat ring states, because the coating time and temperature interact with the above-mentioned operating temperature in a synthetic manner. When the core is small, that is, less than 1 pound, it takes 4 hours. Layers or steam exceeding 73〇τ can cause flat iron cores. Although the temperature may be slightly different, other amorphous metals such as METGLAS 2605SC can also behave similarly. Magnetic amorphous alloys have two technically important grades: transition metals ( TM). Metal-like (M) alloys and rare-earth transition metal alloys. METGLAS2605SA1 and its equivalent are transition metal-based metal alloys, which are broadly included on page 25. This paper applies Chinese National Standard (CNS) A4 specifications ( 210 x 297 mm) (Please read the notes on the back before filling out this page)

508595 A7 B7 V. Description of the invention () One or most of Fe, Co or Ni at about 80 atomic% and B, C 'Si, P or A1 at 20 atomic%. # 2805 alloys are 80% Fe and 20% B, which (please read the precautions on the back before filling this page) are used in the previous generations of the METGLAS2605xxx alloy. The metalloid component is to reduce the melting point 'so that the alloy can be rapidly quenched through its glass transition temperature. At the same time, the same metal also stabilizes the obtained quenched amorphous phase 'and lowers the saturation magnetization and glass transition temperature relative to comparable crystalline alloys. These mainly wanted alloys have been shown to cause very low coercivity and hysteresis loss and very high magnetic permeability because of their expected isotropic characteristics. The combination is important for high frequency applications. However, its weakness lies in the metastable state, which can cause crystallization after removal ' regardless of the presence of metal-like stabilizers. Therefore, a considerable amount of research has focused on the stability and crystallization time constants of TM-M amorphous alloys. This is because the end of life for magnetic applications is considered relative to the setting of crystallization. For a small temperature increase, in the crystallization temperature range, the coercive force and power loss increase, and the remanence and magnetic permeability decrease, all at a rapid rate. This is one of the reasons why the continuous service temperature of METGLAS2605SA1 is set at a relatively conservative 150 ° C. Also, because of this effect, it is possible to adjust the magnetic permeability by tempering the core for a controlled amount of time in the crystallization temperature range. The stability of the TM-M alloy printed by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs has been found to be related to the difference between the crystallization set temperature and the glass transition temperature. Between the melting temperature and the glass transition temperature, Tg, when approaching Tg, the crystallization increases rapidly. On the other hand, when the crystallization setting temperature is lower than Tg, the crystallization decreases rapidly. Therefore, for the discussion of setting the time constant of crystallization, the glass transition temperature is an important parameter. For # 2605 page 26 This paper size applies Chinese National Standard (CNS) A4 (210 X 297 mm) A7

Du 595 V. Description of the invention () The Tg of the alloy is disclosed as 441 X: or 825.8T. Hannover does not disclose the use of Tg for METGLAS 2605SA1 or for any METGLAS alloy. However, it does announce that the crystallization temperature for 2605SA1 and other metglas alloys is 9 4 5 ° F for 2 6 0 5 SA 1, which is about 1 2 0 ° higher than the T g for # 2 6 0 5 alloy. F. Assuming Hanniway's crystallization temperature is τ g, the public crystallization set temperature for # 2605 alloy tempered for a known time is possible or 120 ° F is lower than those used for the 2805SA1 amorphous component. The reason for this large difference is that the 2605SA1 series is very different from the # 2605 alloy in that it chemically adds other elements. Based on this basis and the table shown in Chapter 6 of "Ferromagnetic Materials" (North Holland Press) by Wofar, it is shown that for # 2605 alloy, the crystallization adjustment occurs at 6 0 0-6 1 0 ° F After 2 to 5 hours. Therefore, it is estimated that for the tempering time of 2 to 5 hours, the crystallization may adjust the 2605SA1 alloy to exceed 690 ° F in the range of 720-730 ° F, based on the comparison of the permeability and power loss measurements at 690 卞 and 730 ° F. . This observation is quite consistent with the difference between the # 2605 alloy T g and the published crystallization temperature of the 2 6 6 S A 1 alloy. The data in the following table and related figures are accumulated by selecting two standard Hannover component numbers to test the standard and non-standard coating temperature. The time for maintaining the coating temperature is set to 4 hours, with an additional temperature setting of one hour. time. For this test, the selected component was a "c" core made of METGLAS 2605SA1 with a standard 1 mil gauge and a weight of approximately 0.75 pounds, and the others were approximately 2.5 pounds. The larger core has a window size, cross-sectional area, and path length of approximately 1.8 to 2 times larger than the smaller core, which has a proportionally increased window area and mass. The bandwidth of both iron cores is about 1.2 5 Page 27 This paper size applies the Chinese National Standard (CNS) A4 specification (21〇X 297) (Please read the precautions on the back before filling this page) Order-Ministry of Economic Affairs Printed by the Intellectual Property Bureau employee consumer cooperative 508595 V. Description of the invention (The Intellectual Property Bureau employee consumer cooperative of the Ministry of Economic Affairs printed A7 B7 inches. The bar data and diagrams for the large iron core follow the results for the small iron core. Therefore, for simplicity For the sake of simplicity, only the information of the smaller core is shown. As shown here and in the figure, the noun, "coated" means an iron core that has been slowly combined with heat and steam to form an iron oxide insulating material. Between the layers. The term "uncoated" means an iron core that has not been treated with steam and does not have enough iron oxide to insulate between the layers. In these tests, the data was accumulated using the four-hour process described above, and one hour was set. As a heat model for tempering, foot treatment is replaced by 6 9 0 F, that is, 7 1 5 ° F, 7 3 0 ° F, 7 5 0 T, 7 6 0 卞, 770F, 780 F or 800 卞In addition, the treatment under the standard 690 is also completed in the same test group to compare the results of the special tempering temperature with the results of the standard treatment. In order to better observe the effect of the coatings at the listed temperatures, starting from 890 ° and the range from For a total of 8 stages to 800, the test is done with or without coating treatment. When coating is provided, the treatment is done using the iron-aluminosilicate migration matrix described above. For tests without a coating applied, The heat treatment time is maintained at 5 hours to completely replicate the one hour stabilized tempering time condition and 4 hours of exposure to steam and heating, or 5 hours of total tempering time. The test is completed in three main processing steps : (1) after tempering '(2) after impregnation with epoxy resin, and (3) after final treatment. The longitudinal magnetic field is applied, in which the maximum saturation magnetization can be completed. When a longitudinal magnetic field is applied When used, the noun square (Sq) appears in the following table. When the magnetic field is not used, the noun circle (Rd) appears. Therefore, for most magnetic fields, the Curie temperature exceeding approximately 765 ° C is not used for these tempering conditions. The following intensive tests are performed at 8 different temperatures, a very small "c" core is processed more than page 28: 297 mm) C Please read the precautions on the back before filling this page)

508595 A7B7 V. Description of the invention () (Please read the notes on the back before filling this page) A large number of 690-7 1 ° F and 73 0-745 ° F to ensure the observations completed by the first group. The core has a gross weight of about 0.1 pounds. Subsequent testing of small cores confirms the important conclusions achieved by testing in smaller groups over a larger temperature range. The magnetic permeability parameter is the slope from the zero flux point to the defined flux level due to the zero drive on the magnetization curve. Table 4. Magnetization curve core flux (KG)-immersed with 0.75 # core uncoated drive 690 715 730 750 750 760 770 780 800 800 TT ° F Τ ° FTT ° F ° F ° F 0. 1 0.79 0.58 0.30 0.25 0.25 0.12 0.08 0.04 0.04 0.04 0.5 4.9 4.52 j. J Z 2.9 1 2.66 1.74 1.08 0.50 0.08 0.08 1.0 6.52 6.3 1 5.02 4.73 4.36 3.24 2.4 1 1.29 0.25 0.25 2.0 8.18 8.22 6.72 6.72 6.35 5.15 4.14 2.66 0.7 1 0.7 1 3.0 9.25 9.46 7.80 7.93 7.64 6.43 5.35 3.74 1.3 3 1.12 4.0 10.00 10.29 8.47 8.76 8.4 7 7.35 6.23 4.6 1 1.58 1.49 5.0 10.62 10.96 9.09 9.55 9.30 8.09 7.06 5.35 1.99 1.87 (De) Cube Cube Cube Cube Cube Circle Cube Circle Cube Circle Cube Circle Smart Property All measurements shown in Table 4 printed by the Bureau ’s Consumer Cooperative are done using a magnetic metal constant current flux reset tester (CCFR), which adjusts the appropriate core cross-sectional area and path length to complete a calibration pass Measurement level, unit is thousand Gauss and drive unit is Oster. In addition, the flux density is adjusted to match the saturation level of 1 5.9 thousand Gauss, except for the coated and uncoated treatment of METGLAS 2605SA1 on page 29. This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm) B7 V. Explanation of the invention () Except the result. (Please read the precautions on the back before filling out this page) Table 4 and related Figure 9 show that the approximate decreasing magnetization curve becomes the tempering temperature increasing from 690 to 800 ° F. Furthermore, there are no other square-ring interaction systems in this data that are obvious, except for 690T, 71 5 卞 and 730 卞 data which are used as longitudinal "square-ring" magnetized cores. This result is the result of the immersion stress, because the square system is strongly proved in the prepreg data, that is, the core flux range is from not less than 15KG to 15.9KG, from 30e to the maximum drive 50e for the above temperature. See Figure 16, which shows the magnetization curve for an unimpregnated 0.75 pound uncovered range of 690 卞 to 800T. I believe the reason for this effect is that stress reduces the permeability. See Bo Wo's' 'Ferromagnetism' IEEE Bulletin (Chapter 13, Stress and Magnetization). The applied equation is -l = Bls2 / gs, where 0 is the initial permeability, Is is the magnetization per unit volume when saturated, which is proportional to the saturation magnetic flux density, s is the saturation magnetic limit, and i is Internal stress in a single area. Because the saturation magnetic limit for the 2605SA1 is large, i.e., 27 ppm, a work with smaller immersion stress may be quite large. Table 5 Magnetic permeability and power loss 2KG magnetic flux density, immersion 0.75 # iron core-uncoated factor 690F 715〇F 730T 750T 750 ° F 760T 770〇F 780T 800 ° F 80G ° F Watt # 16.73 10.38 26.99 16.48 10.83 17.50 16.42 17.51 20.56 26.36 Magnetic permeability 9.176 8.198 6.096 5.499 5.115 3.413 2.362 1.315 398 374 The magnetic permeability printed in Table 5 by the Consumers' Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs is calculated in the 2 thousand Gauss magnetic flux, based on the information in Table 4 Calculate. The core loss is measured at 20KHz and 2KG. Page 30 This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm) 508595 5. Description of the invention () (Please read the precautions on the back before filling This page) is used in the testing machine described below and Figure 6. The test conditions for the 2KG power measurement of this iron core are: 4 3 · 9 volts using a 10-turn solenoid coil. The information used for this test is plotted in Figure 10. The power loss is typically higher than the unimpregnated core. Figure 17 is equivalent to Figure 10 for 690 to 800 unimpregnated 0.75 # cores. Note the increased power dissipation for immersed uncut cores. Table 6. Magnetization curve core flux (KG)-immersion 0.75 # core coating drive 690T 715 ° F 730 ° F 750 ° F 760 ° F 760T 760T 770T 780T 800 ° F 0.1 0.54 0.58 0.37 0.12 0.12 0.12 0.08 0.08 0.04 0.04 0.04 0.5 4.15 4.15 3.40 1.70 1.33 1.86 1.04 0.83 0.37 0.08 1.0 5.81 5.93 5.10 3.07 2.49 3.07 2.24 1.87 1.04 0.29 2.0 7.60 7.80 6.97 4.77 4.23 4.86 3.88 3.49 2.28 0.71 3.0 8.76 8.96 8.13 5.93 5.48 6.06 5.06 4.69 3.28 1.12 4.0 9.55 9.79 8.96 6.81 6.39 6,97 5.89 5.56 4.07 1.49 5.0 10.21 10.42 9.67 7.51 7.39 7.72 6.64 6,35 4.81 1.91 (De) Fang Fang Fang Fang Fang Fang Fang Fang Yuan Fang Yuan Yuan YuanThe Ministry of Economic Affairs Intellectual Property Bureau Employee Consumption Cooperatives printed the instructions for use in Table 4 The same applies to Table 6. The coating of the present invention seems to have a slightly greater effect on making a circle or flattening than an uncoated core, depending on the temperature. However, the difference is too small to be noticed by the stress experienced by the core. Equivalent data for unimpregnated cores also show no significant differences between coated and uncoated cores. The difference appears only when the permeability and power loss are considered a crystallization. On page 31 in page 18, the paper size is in accordance with Chinese National Standard (CNS) A4 (210 X 297 mm) 508595 A7 B7 V. Description of the invention () Uncoated and coated iron core is very "square" 'For temperatures below 75 ° F and below' and temperatures at 760 ° F or above are "flat". The impregnation effect used to coat the iron core substantially reduces the magnetic permeability for each tempering temperature, except for 800 ° C. Preferably, the same effect system can be seen on the uncoated core, except that a higher saturation magnetic flux is caused by the tempering temperature of 15 ° F (higher than the tempering temperature of 690 ° F), compared to the unimpregnated temperature. Coated and uncoated cores. The difference between 690 T and 715 ° F is not so great for unimpregnated cores. Table 7- Permeability and power loss 2KG magnetic flux density, immersed 0.75 # iron core-coating factor 690F 715F 730 ° F 750F 750F 760F 760F 770 ° F 780 ° F 800T watts # 8.66 7.19 7.99 11.11 9.56 9.97 11.28 10.5 11.84 22.87 Magnetic permeability 7.639 7.721 6.354 3.284 2.534 3.223 2.233 1.849 1.128 382 The instructions used in Table 5 also apply to Table 7. However, the comparison between Table 7 (coated according to the present invention) and Table 3 (uncoated) shows a clear difference, which can be seen from its isograms, that is, Figs. 12 and 10. These graphs show that the power loss is reduced for the coated core system 'and for the coated core compared to the uncoated core, the permeability is less dissipated for the 2KG power loss. Because the permeability and power loss should be inverse to the relationship of the crystalline region ', other power losses and dissipations for the uncoated core when observing the coated core are due to other things. These differences are not obvious for coated and uncoated cores before immersion, and can be seen by comparing Figure 17 (uncoated) and Figure 19 (coated). Figures 17 and 19 show approximately equal core loss and dissipation. Only when impregnated should be on page 32. The paper size applies Chinese National Standard (CNS) A4 (210 X 297 mm) --- 11 ---- ^ I ------ I · LI (Please read the back first (Notes on this page, please fill out this page).. Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 508595 A7 B7_ V. Description of the invention () Except for the crystalline components where the differences appear. If most of the power loss is due to increased crystallization as the temperature increases, the power loss of the uncoated magnetically permeable pair should show a smooth downward trend. However, because uncoated materials dissipate more than simple crystals can form, other power losses must be greater due to the greater immersion stress compared to the coated core. The conclusion is that it is consistent with the lack of differences between unimpregnated cores and the smaller the difference between the impregnated cores as the tempering temperature increases. When the immersion stress remains constant regardless of the tempering temperature, the crystalline component of the stress becomes larger as the tempering temperature increases. Therefore, for immersed cores, the difference slowly moves to crystals with higher power loss and higher tempering temperatures. Note that for coated and impregnated cores, there is not much improvement at 800 ° F. (Please read the precautions on the back before filling out this page) Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 8-Magnetic permeability & tempering temperature CF) -Immersion 0.75 # Uncoated temperature of iron core ° F 0.1 Oe O .SOe l.OOe 2.0Oe 3.0Oe 4.0Oe S.OOe average 690 7885 9794 6516 4088 3085 2500 2125 5142 715 5810 9047 6308 4109 3154 2573 2191 4742 730 2490 6640 5022 3362 2601 2117 1818 3435 750 2490 5561 4544 3268 2594 2153 1884 3213 760 1245 3486 3237 2573 2144 1836 1619 3306 770 830 2158 2407 2075 1785 1556 1411 1746 780 415 996 1287 1328 1245 1152 1071 1070 800 415 166 249 353 408 384 386 337 Page 33 This paper is applicable to the Chinese National Standard (CNS) A4 specifications (210 X 297 mm) 508595 A7 B7___ 5. Description of the invention () (Please read the notes on the back before filling this page) The magnetic permeability in Table 8 is calculated from the data in Table 4. For each The combination of temperature and drive level becomes a magnetic flux density measured as a known drive level. Note the depression at 73 ° F in Figure 13. For METGLAS2605SA1, 730 ° F is the estimated theoretical temperature set by the 5-hour tempered crystallization. Figure 13 shows a fairly stable permeability range from 0.1Oe to 5.0Oe, transitioning to a fairly steep slope, starting at about 75 ° F or slightly higher. This average is reasonably linear over a logarithmic permeability versus temperature plot above 750 ° F. At the same time, the permeability changes quite slowly beyond the range of 0.10e to 5.OOe and above 750 ° F, except for abnormalities at very low 0.1Oe levels. The magnetization curve was changed from "circle" to "flat" ring in the range of 730 to 750 ° F. Table 4 and Figure 9 show the same effect. Table 9-Magnetic permeability & tempering temperature (° F)-immersion 0.75 # iron core coating temperature. F O.lOe O.50e l.OOe 2.0Oe 3.0Oe 4.0Oe 5.0Oe average 690 5395 8300 5810 3818 2919 2386 2042 4381 715 5810 8300 5935 3901 2988 2449 2083 4494 730 3735 6806 5106 3486 2711 2241 1934 3717 750 1245 3403 3071 2386 1978 1702 1502 2184 760 1107 2684 2601 2158 1844 160 1450 1921 770 830 1660 1878 1743 1563 1390 1270 1475 780 414 747 1038 1141 1093 1017 963 916 916 800 415 166 291 353 374 374 382 336 Economy The magnetic permeability printed in Table 9 by the Consumers ’Cooperative of the Ministry of Intellectual Property Bureau is calculated from the data in Table 6, and it is used in accordance with the Chinese National Standard (CNS) A4 specification (210 X 297) per page 34. (Centi) 508595 A7 B7 V. Description of the invention (1) A combination of temperature and driving level 'in the ratio of magnetic flux density to a known driving level. Note in Table 8 that the concave under 7 3 0 F' has been used in The limited tendency in Table 9 is replaced downward See Figure 14. The coating system of the present invention assists in migrating at slightly lower temperatures. The logarithmic-permeability versus temperature map in Figure 14 shows that the Arrhenian nature is more apparent than in Figure 13 and begins Faster, that is, 740T. All other observations completed from Table 8 are applicable to Table 9. The larger 2 · 5 # iron core shows the same tendency as the smaller 0 · 7 5 # iron core, with slightly different saturation inductance and magnetic permeability. Specifications and functions: Table 1Q is used at 20KHz and 2KG, and the power loss data taken from the $ temperature used for the data collection point, which starts at 690 ° F and ends at 800T. 0 · 75 pounds (# ) Iron core is used. 2.5 pound iron core shows similar results. -N ϋ In nnn an Mmmmatm lap emm§ emmmmm I-0 mmm — el (Please read the precautions on the back before filling out this page) Staff of the Intellectual Property Bureau of the Ministry of Economic Affairs Printed by Consumer Cooperatives

This paper size applies to China National Standard (CNS) A4 (210 X 297 mm).

508595 A7 B7 V. Description of invention () 770 round 4.63 4.54 10.5 16.42 10.7 one one _ 16.18 34% 780 round 7.52 5.74 11.84 17.51 — 11.36 18.19 38% 800 square 21.24 20.56 one ----- 13.63 16% 800 round 23.21 21.24 22.87 26.36 -------- 13.29 17.87 The tempering conditions marked as square indicate that the 75 ampere DC system flows through the core window, thereby creating a substantially longitudinal magnetic field tempered on the "JE square" magnetization curve. Tempering conditions It is marked as a circle, which means that the current flows through the window of the iron core, and there is no magnetic field for tempering. The "no data" at the completion of the tempering condition of 730 卞 is caused by the loss of the iron core. The percentage of indication used for each tempering temperature Fan Yuan is the average of the round and square conditions, if both are available. If the range of 6 9 0 T to 8 0 ° F is taken as the whole, there is a total improvement of 30%. The apparent permeability of the core is strongly influenced by the size of the gap (if there is a gap) as follows: Ι / a 丨 f = l / i + g / p, where aff = core is effective or the permeability is measured, 1 = test Under the conditions, the inherent permeability of the core material, that is, the magnetic flux and frequency, g = total gap, p = average path length in the direction of the magnetic flux in the core. Note that alf = i, when the gap is zero. Permeability in the CGS system is unitless. The formula is reduced to alf ^ i / ^ l + g / pXi), where g and p have the same size. Is equal to alt, pβ, when g / p > &l; l.

Assuming this gap uncertainty, the CCFR instrument set used to measure the permeability of the uncut core is not appropriate for the cut core. At the same time, CCFR has not corrected the 20KHz frequency equivalent to the power loss test points of 2KG and 20KHz. In order to overcome these problems, a general radio 1 630-AV page 36 This paper standard applies to China National Standard (CNS) A4 specification (21G X 297 public love) -------- r --- · --- Install LI (Please read the notes on the back before filling this page) Order *-Printed by the Employees 'Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs Printed by the Employees' Cooperatives of the Ministry of Economics and Intellectual Property Bureau Printed by 508595-~~ ——___- V. Description of the Invention () Inductance measurement module is used to measure small coated C core < inductance with carefully controlled gap size. However, there is no excitation difference between CCFR and the inductor bridge. CCFR uses a sine wave current and the inductor bridge uses a sine wave voltage. The difference in excitation between the two testers will affect the comparison of permeability. The magnetic permeability 4 measured by the bridge is slightly larger than C C F R. However, these differences are not considered large enough to affect the nature of the results obtained from these tests. The following formula is used to calculate the given inductance and the known gap #

Al / (4x1 (^ XN2xAgif / -g), where n is the number of revolutions, Agif is iron ~ effective area, in square centimeters, # = inductance of the iron core, the unit is Yuli 'and g (previously defined) is expressed in centimeters As mentioned earlier, i does not have a unit size in the CGS system to report this information. The formula used to calculate each gap includes the mating surface gap. All magnetic permeability calculations are completed at 2KG and 20KHz, using 50 turns of the coil, symmetrical It is placed on the two gaps to reduce the ignition effect. Therefore, the result can be compared with the core loss measurement under the same conditions. The calculated value of the magnetic permeability is applied to a straight line using regression technology to estimate the magnetic permeability of the material as " yn blocking 'is equivalent to zero clearance. The accompanying power loss data was measured as above. The following data shows the results for a 0.1 pound "c" core. Table 11 compares Wu to 0.1 pound, C "core Magnetic permeability and power loss, the core is tempered and coated at 690 T for four hours, using the standard processing conditions for the square ring π requirements. The table compares the standard "square ring" and "ring" "At Table 1 1 The permeability estimation is obtained after cutting, using a regression technique to obtain the calculated permeability, and applying the calculated permeability to the measured gap. The permeability calculation is completed in various gaps, and a standard formula is used in conjunction with a linear regression. V paper size applies Chinese National Standard (CNS) A4 specification (210 X 297 mm) ~ -------- iM Pack II (Please read the precautions on the back before filling this page) «·

508595 A7 B7 V. Description of the invention () line. The obtained regression lines are extrapolated to zero gap to provide the permeability estimates (after cutting) for circles and square rings as shown in Table 11. Note that the permeability at the cut is applied to an average of 5 cores and used in each cluster to improve the estimation accuracy. The gap measurements in Table 12 are rounded down to three places. Correctness is necessary so that the closest value calculated by regression analysis can be generated. The gaps are actually checked to 0.0001 " using an optical comparator. The information obtained is adjusted by regression techniques and is not greater than the limit of accuracy. This adjustment is done to get the best possible fit. Figure 20 shows the obtained regression line and the data corresponding to Table 12. --------- ί --- ί — --- (Please read the notes on the back before filling this page) Table 11. Comparison of Permeability and Power Loss Before and After Cutting -0.1 # Permeability of Iron Core Condition Core Loss (Watts) Before Cutting After Cutting After Cutting Before Cutting After Cutting Square Ring 5142 ± 847 4782 8.55 ± 1.20 8.91 ± 4.04 Round Ring 4914 ± 1193 4298 8.82 ± 0.81 9.13 ± 1.59 ·! Line. Intellectual Property Bureau, Ministry of Economic Affairs, Consumer Consumption Cooperative The magnetic permeability and core loss data printed before cutting are obtained after immersion, and each condition is the average of 10 cores. The magnetic permeability data after cutting are at the core completion stage, and each condition is the average of 5 cores. The magnetic permeability data before cutting were obtained using a CCFR tester at 400HZ. The magnetic permeability data after cutting were obtained at 20KHz using an inductive bridge. ± xxxx is 3x (standard deviation). All cores were treated in Nanlai under standard tempering conditions of 690 ° F. Article 38 " M * This paper size applies to China National Standard (CNS) A4 (210 X 297 mm) 508595 Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs

璧 Measurement gap (mil) Protruding without gap 0.6 5 (fitting gap) 2.4 (amber 2_ 3.2 (purple)

It is used in the circle, and it highlights the gapless data segment. Note the error between adjustments. Figure 20 shows the magnetic permeability of the material obtained from the nose A7 B7

Apparent; Magnetic permeability of the material-0. 丨 # 铁心 g ^) Adjust the gap (cm) Ring square ring 0 4298 4 7 82 0.00165 5490 8692 One 0.00608 One ..._ 1 1 1 0823 1 8 3 3 9 0.00806 1 3224 2 1808 0.00940 ------- 1 2322 26757 The regression coefficients of the ring are 0.92 and 0.99, respectively. The magnetic permeability is estimated in Table 1 after "cutting, and the regression variation in which the step gap does not exceed 0 · 1 mil is also measured / reproduced in Table 12, showing the regression overlap. The calculation does not remain the same, because there is Two reasons for the gap change. First, for good soils, the% /, material permeability calculation system is particularly sensitive to the gap size as previously discussed. Because it is not possible to measure the gap to the required accuracy, historical regression techniques It is used to adjust the uncertainty of the gap. Second, the edge magnetic flux tends to cause 'the inductance increases proportionally when the gap is proportional to the increase. This is a documented effect that inductor designers must consider. However, the simple formula used to calculate the permeability in Table 12 does not take into account the complex edge magnetic flux effect. Because the effect of the edge magnetic flux is to increase the inductance value, and it is also increased when the gap is increased. The role of magnetic permeability of materials. This is the main reason why regression analysis is needed, because no. The paper size on page 39 applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm) (Please read first Note the surface to fill out this page)

A7

5. Description of the invention () It will be impossible to know the slope of the edge error effect. The regression technique allows the estimation of the permeability of the material to be reduced to zero clearance by reducing the magnitude of the effect. Book frost treatment to improve performance The improvement provided by the present invention is mainly due to a reduction in power loss, which occurs gradually. There is no improvement without a coating. A thin coating results in better power loss improvement in the "uncoated" state due to a slight decrease in eddy current. When the coating gradually increases' first because the coating thickness increases rapidly, other improvements occur quickly. At this stage The eddy current quickly disappears when the resistance of the coating increases with the thickness. However, at some points, the thickness of the coating increases slowly. When this occurs, the performance improvement also slows down at the same time, because the thickness no longer increases and the eddy current reaches a balance. State. This is the general "Sπ curve" of the substrate used for the growth process. At this time, the metallic material provides iron to the coating as the insulated iron oxide. Crystallization is also time-dependent because of "setting effect". Therefore, if the tempering is sufficiently long in the coating treatment range, crystallization starts. Once crystallization has begun, it is only a matter of time before the negative effects of the obtained efficiency, that is, the decrease in magnetic permeability and the increase in coercive force and power loss. Because coating growth and crystallization are driven by temperature, when the temperature is lowered to a level that is preferably below 500-600T, both processes are slowed or stopped. This "freezing," a modification of the positioning accuracy into a coated product, allows the performance measurement of the cold treatment state. This assumes that crystallization has not started. Therefore, the benefits increase first, and then decrease with time and temperature increase. The complex relationship between these competing effects. For example, 'The coating can be page 40. The paper size is applicable to the Chinese National Standard (CNS) A4 specification (210 X 297 mm). . Bu 丨 (Please read the notes on the back before filling this page) Order: Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 508595 A7 ---------— B7_____ V. Description of the invention () Application, by exposure to steam and heat, for a first time period, followed by or most subsequent steam / heating treatments. Measurements of permeability and power loss can be completed between successive coating steps. First, there will be improvements Then, when the eddy current decreases, the competitiveness decreases, and the crystallization work opposes each other. This is clearly to determine the safety time and degree range and power loss requirements for the known permeability. Because the main limiting factor is the crystallization design Therefore, the amount of processing time at any given temperature can be estimated from the graph. For example, 690-7 1 5 T, using the table in Chapter 6 of the method, it can be estimated that there is 1 before the crystallization setting at the beginning of METGLAS2605SA1. 〇 15 hours of tempering is available. This allows 丨 to 2 times of general processing conditions to repeat the "climbing" of power loss for 5 hours for square ring processing. As a result, because of the material change, the first coating treatment does not occur For iron cores with desired properties, one or most other processing times can sometimes be used to improve the effectiveness of the coated core to the desired level. Of course, as noted above, each additional treatment should be within the limits of the material to allow crystallization It does not exceed the other processing margins. Measurement and repeated processing must occur before immersion. The following shows how this reduction is achieved. The data is taken from the pound ring, made by METGLAS2605SA1, and designed to be used for very high In the power transformer assembly, the data report shows that the stacking resistance was improved to 69〇τ for the first coating of six hours. Then, the cooling and resistance measurements were performed, and then, the second coating was applied. 690T 6 hours, or a total of 12 hours including the original processing. Increasing the stacking resistance is roughly related to the improvement with a core. Page 41 This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm). (Please read the precautions on the back before filling this page) ·. Printed by 508595 A7B7, Employee Cooperative of Intellectual Property Bureau of the Ministry of Economic Affairs 5. Description of the invention () Table 13-40 lbs. METGLAS2605SA1 ring DC stacking resistor core No. 1-6 Hours of coating treatment stack 2-6 hours (total 12 hours) Coating treatment stack 24 314 880 + 180% 26 267 347 + 30% 29 295 841 + 185% 30 130 546 + 320% 31 356 836 + 135% 32 1456 1295-11% 33 814 1603 + 97% 34 965 2031 + 110% 35 869 1485 + 71% 36 996 2192 + 120% 38 769 1596 + 108% 39 715 1704 + 138% 40 915 2645 + 189% 41 534 2095 + 292% 42 721 2218 + 2-8% 43 530 885 + 29% 44 1200 1490 + 24% 45 1238 1413 + 14% average change + 124% net average improvement (please read the notes on the back before filling this page) Printed by the Consumer Property Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs of the 1 2 4% net average improvement is significant. Only one part of the 18 reprocessings decreased slightly, namely -1 11%. Page 42 This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm) 508595 A7 B7 V. Description of the invention () Examples The following examples show the invention. The excellent characteristics of the iron core can be produced by the treatment of the invention. . For the following example, the power dissipation in the C iron core is connected by a voltage and current watt (v-A-W) meter (Clark and Hess Digital of New York) and a 2MHz function generator (Chicago, McTe International company, model BK Presion 3011B) 'to one kilowatt amplifier (model LB from San Diego, Calif., Inc.) to control output, shaping and amplitude frequency and measure it. A sine wave having a variable size and frequency is then applied to the C core via one of two possible turns. The coils are wound around the C iron core and connected to the output connection of the kilowatt amplifier. The typical measurement conditions applied to the iron core depend on the desired flux, and the representative examples are as follows: (Please read the precautions on the back before filling this page) Printed for the C iron core by the Consumer Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs Electrical setting conditions for measurement Frequency (KHz) Excitation voltage (volts) Required flux (KG) Required turns 0.4 14.6 2.0 50T 0.4 36.6 5.0 50T 0.4 72.6 10.0 50T 0,4 109 15 50T 1.0 3.6 2.0 5T Voltage transformer 1.0 9.26 5.0 5T with step-down transformer 10.0 36.6 2.0 5T ______ — «—-20.0 73 2.0 5T _ The above combination is not unique, it must be selected & achieve the required magnetic flux level. This paper scale applies to China Standard (CNS) A4 specification (210 X 297 mm) 508595 A7 ----_---- B7 ____ V. Description of the invention () " 一 '^ These levels are set using precise function generators, By reading the value of the 7-function generator, the voltage reading and display settings of mw I are added, and the V_A-W meter directly measures the core power loss and the excitation power> Watt's use of power measurement and current measurement set up. In order to measure the power dissipation of the pulse ring, a pulse generator (HP type 214A), a high power pulse generator (Stanford Cooper Electronics Co., Ltd. model 608)) and an adjustment power supply (New Jersey, Harrison at Buckley Heights ^ Test 1: Model 814A) is connected to a vacuum tube pulsator to control its output rise time, duty cycle and amplitude for repeated pulse conditions. The vacuum tube pulsator is a three-turn coil connected to a high-amp cable, which is wound on a ring. The setting is insulated because high voltage is generated. An oscilloscope (Philip model PM3323 50DMS / S with 30kv probe) is used to record the green pulse shape, the core excitation distribution and integrated power are reflected in the memory. The typical measurement range for pulse width is from 1.5 to 3.0 microseconds, 15-20 amps on DC reset, with pulser adjustment to complete 1-4 Tesla magnetic flux in the core. The pulse test equipment is illustrated in FIG. 6. Example 1 Reduced power loss For example, a wound core of an amorphous metal alloy of METGLAS 2605SA1 with about 70% iron is tempered at the same time, and then steamed (pH 8) and 3 65 are used. (69 0 ° F) air treatment for 6 hours to form an iron metal oxide insulating material between the adjacent metal strips of the core. Two clusters of iron cores were formed. The first group contains iron cores weighing approximately 5 pounds each, and the second group contains iron cores weighing approximately 1 pound each. Page 44 Paper-size Folding Order Household Products (CNS) A4 (21G X 297 mm) '' I- ---------- ί ^ * l · I (Please read the notes on the back before filling this page} Order ··

Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 508595 A7 B7 V. The iron core of the invention description (). The power loss is normalized between the two groups by dividing the power loss by the core weight. The second group of cores consisted of two groups, which were completed as described above, but were not treated with steam and air. As a result, this group of cores lacked iron oxide insulation and was used as a basis for comparing the power loss of the processed cores. The normalized information is shown in Table 14 below. Table 14 > nnnnn (^ I ^ > am · MW face · Hi I (please read the notes on the back before filling this page) Compare the power loss of treated and untreated amorphous iron cores as a function of frequency Power loss of processing core (W / lb) Frequency (KHz) Unprocessed processed improvement% 0.4 1.9 1.3 14 1.0 3.9 2.7 17 10.0 13 9.9 30 16.0 27 19 33 20.0 17 9.0 45.%-Consumption by employee of Intellectual Property Bureau, Ministry of Economic Affairs The data printed in Table 14 of the cooperative shows that the iron core generated by the iron core of the amorphous iron alloy treated by the method of the present invention has an improvement of 1 to 45% lower than that of the untreated iron core at high frequencies. That is, the The power loss is reduced from 14% to 45%. Furthermore, the improvement in performance increases with increasing frequency, as described above. A similar experiment was performed with fine crystalline materials, such as 70% Fe, 9% B, Page 45 This paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 mm) 508595 V. Description of the invention () 3% Nb, 2% Cu and a small amount of Mo,. The formed core force ρ is performed. These cores are Tempered at about 58.0 (under 1000), cooled to room temperature, and then processed to form an iron oxide insulating layer. The reduction in power loss of these cores is compared to that of untreated fine crystalline core systems. Similar to what is seen in the amorphous metal alloy cores in Table 14. Example 2 Comparison of iron cores treated with steam and air and iron cores treated with methyl manganese in a pulse test The magnetic core consists of about 1 mil thick amorphous iron A belt, such as METGLAS2605SA1, is formed as a ring pulse iron core with an outer diameter of 197 cm (7 · 75 ”), an inner diameter of 10.8 cm (4.25”), and a thickness of 51.1 cm (2 ,,). It is coated with methyl manganese, or treated with steam / air after winding to form an iron oxide insulating layer, or both, as described in Table 15. The iron core is used by applying about 8.6 kV. Low frequency duty cycle, once every 5 cycles, lOpps and pulse energy calculated from 3 microsecond pulse width and 2.85T magnetic flux. Pulse data measurement includes core power (the amount of power dissipated by the core), starting current, and saturation Current, pulse energy The area of the pulse curve multiplied by the voltage is calculated to obtain the Joule amount of power. In all measurements, the lower the number, the better the core. Furthermore, preferably, the starting current is as close to the saturation current as possible. Test results This is shown in Table 15. Page 46 This paper is sized to the Chinese National Standard (CNS) A4 (210 X 297 mm). Γ Qing first read the note on the back? Please fill in this page again} Order. · Printed by 508595 A7 B7, Consumer Cooperatives of Intellectual Property Bureau of the Ministry of Economic Affairs 5. Description of the invention () --- Ϊm " 4u " · Manganese-5 Jinqi / Air treatment core pulse data test processing Core power (kW) Starting current (A) Saturation current (A) Pulse energy (Joule) 1 Immersion in oil, methyl, steam / air 201 20 38 0.75 2 Methyl, steam / air 204 20 40 0.77 3 Photoresin impregnation 287 30 50 1.0 4 heavy resin impregnation, steam / air 331 30 60 1.2 5 oil impregnation, steam / air 196 22 32 0.7 6 methyl manganese 200 20 40 0.8 --------.---.-- -Packing ·! .1 (Please read the notes on the back before filling this page) All the iron cores in Table 15 are amorphous metal alloys, and iron is the main metal. For the core of Test 1, the amorphous metal ribbon was coated with very thin methyl manganese, the ribbon was formed as a laminated core, and steam and air were applied, by first tempering at about 366t (69 (TF)) Hours, and then treated with steam (pH8) and air at 304 C to 316 ° C (580-600T) for six hours to form an iron oxide insulation layer. The core is then immersed in oil. During the pulse test, the core vibrates, and the oil system It was added to help protect the core during the test. At test 2 of the core, the band was coated with very thin methyl manganese and wound into a laminated core. The core was then treated with steam / air in Example 1. Core test 3 is made by winding an amorphous metal strip into a laminated iron core and treated with% vapor and $ gas as shown in Example 1. The treated iron core is then impregnated with photoresin. Iron core test 4 is the same as iron core test Formed and impregnated with heavy resin. Iron core test 5 is a series of amorphous metal alloy wound into a laminated iron core. The paper size is applicable to China National Standard (CNS) A4 (210 X 297 public love) -----

Printed by the Consumers ’Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs A7 B7 V. Description of the invention (formed 'and then treated with the steaming air shown in Example 1. Iron', and finally" 'similar to the test! Iron core. Iron core Test # 6 is made by coating an amorphous metal strip with a very thin methyl core. I々V becomes a laminated iron. As shown above, the emulsified iron insulation layer treated with steam and air during the pulse test is roughly performed as The power or f of the iron core formed by the methyl band is better. Better, however, '-,,,' completed with steam / steam air is faster and costs less than coating with a thin layer of methyl manganese. Eight pulse iron cores coated with methyl manganese and impregnated with resin ruptured during the test, for which reason it is not shown in Table 3 ..., as the data does not show in the processing to oxidize by natural metals%, for example The pulse iron core formed by the iron oxide is more flexible than the pulse iron core formed with a methyl manganese coating. If the resin-coated iron core is used in tests 3 and 4 to simulate the combination with the sword treatment, it will be cut before the core is formed into a C iron core. To complete. Even dip The power loss of Shuyue E1 iron core is enough for the steam / air treatment iron core. The power loss of the iron core is 40-50% lower than that of the iron core not impregnated with resin. Increased power dissipation. Efficiency vs. processing temperature Table 16 below shows the effectiveness of iron as the main metal in the treatment of amorphous metal cores under different temperature conditions. The cores used are all about 5 pounds and have about 5.1 cm (2 ") Broadband. So the iron core is treated with steam in the air for 4 hours and tempered for 2 hours, except that the iron core is tempered at the same time and the private paper size applies the Chinese National Standard (CNS) A4 specification (210 X 297 male feet- ------ One --- install.L1 (Please read the notes on the back before filling this page) Order: Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 508595 A7 __B7__ 5. Description of the invention () (please first Read the notes on the reverse side and fill in this page again) Treatment outside. The latter is tempered and steam treated for 4 hours at the same time. The same set of cores are treated and tempered, but not exposed to steam / air to form an iron oxide insulation coating The power loss of each group of cores is measured and compared as follows. Table 1 6. Relative performance of iron oxide coatings on C cores compared to uncoated structures. Processing condition frequency (kHz) 0.4 1.0 10.0 20.0 500 ° F processing 690 ° F tempered 9.0% 4 3.9% 2 1.1% 19.8% 550 ° F tempered 690 ° F tempered -19.5% 12.9% -71.5% -77.0% 590 ° F tempered 690 ° F tempered -5.7% 2 2.2% -53.1% -57.3% 625 ° F treatment 690 ° F tempering -1.0% 3 8.1% 18.2% 17.8% 650 ° F treatment 690TF tempering -4.3% 3 1.2% -12.7% -18, 5% 6 9 0 ° Simultaneous tempering of F treatment 2 2.8% 5 2.2% 5 0.2% 52.7% Core loss is expressed as% improvement (reduced) compared to comparable uncoated architecture Printed by Employee Consumer Cooperatives of Intellectual Property Bureau of the Ministry of Economic Affairs Table 1 6 Response by using pH The data of the enhanced steam taken from the iron core, the p 系 enhanced steam system is about p Η 8 -10, and a steam generator uses feed water from a reverse osmosis system. For comparison purposes, Figure 5 (Table 14) shows the same core architecture treated with impure water as a pH of about 8. Example 4 shown in Table 17 is a comparison of uncut toroidal cores of various weights. The core is formed of an amorphous metal alloy such as METGLAS 2605SA1. P.49 This paper size is in accordance with Chinese National Standard (CNS) A4 (210 X 297 mm) 508595 A7 B7 5. Description of the invention () Main element metal. The iron core is tempered at 3M C (690 F) for 2 hours' and then treated with steam / gas at 3 0 4 ° C to 3 1 6 C (5 8 0 ° F -6 0 0 ° F) for 2-6 hours. . As can be seen from Table 5, for higher frequencies of 20 kHz, the core with the insulating coating of the present invention exhibits a significant reduction in power loss. Table 17-Is there a power loss of steam / air? The age of the uncut core structure is low frequency 400Hz high frequency 20KHz 400Hz ------- 20KHz heavy (broken) untreated processed untreated processed impedance impedance 0.83 2.2 watts / # 2.9 watt / # -31% 0.92 1.8 watt / # 2.2 watt / # is m 7.2 watt / # -19% 46% 1.24 1.4 watt / # 2.0 watt / # -41% 2.68 29 watt / # 5.8 watt / # 80% ££ 5 1.9 W / # 2.2 W / # 58 W / # 18 W / # -21% 69% λ24 1.4 W / # 2.0 W / # 13 W / # 10 W / # -44% 23%- -------- Install l · — (Please read the precautions on the back before filling in this page) Order: Example METGLAS2605SA1 iron core is tempered at 690 ° F for 2 hours, and then it is about 3 0 4. (: To 3 1 8 ° C (5 8 0 ° F-6 0 0 ° F)) steam / gas treatment for 2, 4 or 6 hours. As shown in Table 18, the power loss seen roughly follows steam /. The gas treatment time is increased from 2 to 6 hours and reduced. Page 50 Uses Chinese National Standard (CNS) A4 (210 X 297 mm)

Printed by a member of the Intellectual Property Bureau of the Ministry of Economic Affairs / Consumer Cooperative, one sheet of J / paper 508595 A7B7 V. Description of the invention () Table 1 8- Power dissipation of processing time at two frequencies (Watt #) # Processing time (minutes) Dissipation (400Hz) dissipation 20kHz 1 120 1.9 18 2 120 1.6 17 3 120 1.5 16 4 120 1.5 16 5 120 2.1 22 6 120 1.9 19 7 120 3.0 12 8 120 2.2 20 9 240 1.3 15 10 240 1.5 13 11 240 1.6 17 12 360 10 13 360 17 The results reflect the normalized information that the weight of various core structures has increased from less than 1 pound to slightly more than 7 pounds (please read the notes on the back before filling out this page) The present invention and its advantages have been described in detail with reference to specific embodiments thereof, but it should be understood that various changes, substitutions and alterations can be made without departing from the scope and spirit of the invention. The scope of the invention is determined by the following As defined by the scope of patent application. P.51 This paper size applies to China National Standard (CNS) A4 (210 X 297 mm)

Claims (1)

508 508 | 8 胗 9 异 8 ^ Positive buttocks & 屻 m words, spears, cans and cans + |, discrimination and six, patent application scope 1 · Adjacent metals that provide dielectric insulation in a laminated magnetic component An interlayer method, the method comprising at least the steps of: providing a laminated magnetic component having a plurality of layers, wherein portions of the layers are formed of iron; and oxidizing the layers to produce an insulating coating, the coating comprising Iron oxide is between the layers. The oxidized magnetic component exhibits a power loss reduction of at least 15% at an operating frequency of WkHz to 20kHz, compared to those having substantially the same size component without an insulating coating. 2. The method according to item 丨 of the scope of patent application, wherein the above-mentioned oxidation step includes exposing a plurality of layers to steam, and the presence of oxygen at a temperature of at least 500 ° F. 3. The method as described in item 2 of the patent scope, wherein the above-mentioned layers are exposed to a temperature from 500 ° F to 800T. 4. The method as described in claims 1, 2 or 3, wherein most of the above layers include an amorphous metal alloy. 5. The method according to claim 1, 2 or 3, wherein most of the above layers contain a fine crystalline material. 6. The method as described in item 1 of the scope of patent application, wherein the above-mentioned acoustic magnetic component is a wound core. Chapter 52: This paper size applies to China National Standard (CNS) A4 (210 X 297 mm) I --------- It --------- (Please read the precautions on the back first (Fill in this page again) i §88508595 Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 7. The method as described in the patent application item i, wherein the laminated magnetic component described above includes stacked metal layers. 8. The method as described in item (i) of the scope of patent application, wherein the above-mentioned oxidized magnetic component exhibits a reduction in power loss of at least 30%. 9. The method as described in item (i) of the scope of patent application, wherein the above-mentioned oxidized magnetic component exhibits a reduction in power loss of at least 45%. ι〇. The method described in item i of the scope of patent application, further comprising supplying iron oxide cations to the laminated magnetic component from an external source, when the laminated magnetic component is oxidized. 11. The method described in item i of the scope of patent application, further comprising supplying iron oxide (Fe2O3) to the magneto-optical component through steam, while the layers are being oxidized while β 12 The method further includes exposing the laminated magnetic component to its tempering temperature for a period of at least 2 hours. 13. The method as described in item 1 of the scope of patent application, further comprising exposing the laminated magnetic component to a time period of at least two hours of at least its crystallizing set temperature '. 14. The method described in item 丨 of the scope of patent application, further comprising measuring the magnetic or electrical characteristics of the oxidized magnetic component 'then' further oxidizes the oxidized magnetic part illlllllllu I I-* · --- I ^ «— — — — — 1 —. (Please read the notes on the back before filling this page) Page 53 508595 A8 B8 C8 D8 9L 8. 2, ^ year. Month κ * · Printed by the Consumers' Cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs, the layers of the scope of patent application to increase the amount of insulation coating. 15 · A soft magnetic component comprising a plurality of metal layers, wherein an insulating coating is formed between adjacent layers of the plurality of metal layers, and the insulating coating is basically composed of an oxide formed by oxidizing iron on the layers. 1 6 · The soft magnetic component described in item 15 of the scope of patent application, further comprising: a long amorphous metal belt including the group #, the belt is at least 40% iron, the belt has a first side and a On the second side, the first side has small protrusions and the second side is substantially smooth; a strip is wound to form a laminate including adjacent metal layers, so that the protrusions on the first side contact the smooth second surface; The insulating coating substantially covers the smooth second surface and covers at least a part of the protrusions, and if the insulating coating contacts the smooth second surface, the coating has a thickness of 0.00 μm or more. 17 · The soft magnetic component according to item 16 of the scope of the patent application, wherein more than 75% of the above coatings include iron oxide (111) and iron oxide (11-111). 18. The soft magnetic component described in item 16 of the scope of patent application, has a resistivity greater than 500 ohm centimeters. 19. The soft magnetic component as described in item 16 of Shenyan's patent scope has a resistivity greater than 100 ohm centimeters. Page 54 ...... Meal ............ 、 玎 ：; ------ S (Please read the notes on the back before filling this page) 508595 A8 BB C8 __—__ D8 6. Scope of patent application 20 · The soft magnetic component described in item 16 of the scope of patent application has a resistivity greater than 10,000 ohm cm. 2 1 · The soft magnetic component according to item 16 of the scope of patent application, wherein the metal layer comprises an amorphous metal alloy. 22. The soft magnetic component according to item 16 of the scope of patent application, wherein said metal layer comprises a fine crystalline material. 23. — A dielectric insulation coating between the contact points of adjacent metal layers of a soft magnetic component. The coating contains a sufficient amount of the main iron oxide to reduce the power loss in the component by at least 15% at 10 kHz. Or higher. 24. The dielectric insulation coating according to item 23 of the scope of the patent application, wherein a sufficient amount is sufficient to reduce the power loss in the module by at least 30%. Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 25. The dielectric insulation layer as described in item 24 of the scope of patent application, where a sufficient amount is sufficient to reduce the power loss in the module by at least 45%. Page 55 This paper is sized for China National Standard (CNS) A4 (210 X 297 mm)