WO1996005603A1 - Manufacturing of ferromagnetic film for transformer and motor cores - Google Patents

Manufacturing of ferromagnetic film for transformer and motor cores Download PDF

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Publication number
WO1996005603A1
WO1996005603A1 PCT/SE1995/000911 SE9500911W WO9605603A1 WO 1996005603 A1 WO1996005603 A1 WO 1996005603A1 SE 9500911 W SE9500911 W SE 9500911W WO 9605603 A1 WO9605603 A1 WO 9605603A1
Authority
WO
WIPO (PCT)
Prior art keywords
iron
film
ferromagnetic
film according
ferromagnetic film
Prior art date
Application number
PCT/SE1995/000911
Other languages
French (fr)
Inventor
Peter Nygren
Original Assignee
Peter Nygren
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Peter Nygren filed Critical Peter Nygren
Publication of WO1996005603A1 publication Critical patent/WO1996005603A1/en
Priority to SE9700455A priority Critical patent/SE9700455L/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0233—Manufacturing of magnetic circuits made from sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/14—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for applying magnetic films to substrates
    • H01F41/22—Heat treatment; Thermal decomposition; Chemical vapour deposition
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/14—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for applying magnetic films to substrates
    • H01F41/24—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for applying magnetic films to substrates from liquids
    • H01F41/26—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for applying magnetic films to substrates from liquids using electric currents, e.g. electroplating

Definitions

  • TITLE Manufacturing of ferromagnetic film for transformer and motor cores.
  • the invention relates to the manufacturing of a film according to the precharacterizing part of claim 1 which consists of a ferromagnetic thin film for the manufacturing of magnetic cores for transformers and electrical rotating machines.
  • magnetic cores for transformers and electrical rotating machines are manufactured today with thin (approximately 0,25 - 0,5 mm) silicon alloyed iron plates with an intermediate insulation to reduce the losses due to eddy currents .
  • the plates are placed together to form a core.
  • the plate is normally manufactured with an orientation of the directions of the crystals .
  • the manufacturing of the core is time-consuming, the cores are heavy and the magnetic permeability is relatively low in normal silicon alloyed plates.
  • the purpose of the invention is to achieve a very thin and flexible ferromagnetic film with a high magnetic permeability and orientated crystal direction for the manufacturing of transformer and motor cores.
  • the losses due to eddy currents can be kept very low. Since the losses due to eddy currents are proportional to the square of the thickness of the plate, they are reduced 625 times if the thickness is 10 ⁇ m instead of the normal 0,25 mm. If the material does not contain silicon, the difference is reduced somewhat (approximately 6 times) .
  • High magnetic permeability increases the inductance and therefore the number of winding turns and the height of the core can be reduced and therefore also the size and wheight of the transformer.
  • the initial permeability for silicon alloyed orientated plate is 1.500 Vs/Am whereas it is for example for iron carbonyl 10.560 Vs/Am.
  • the flexible film makes the manufacturing of the core much simpler and quicker - the parts of the core can simply be rolled together or transported to the transformer manufacturer as prefabricated rolls and therefore the productivity is increased and the transformer cost is reduced.
  • the cost ' of the film can be kept low through cheap raw material and a continuous manufacturing process. * Lower noise level thanks to higher mechanical damping.
  • Figure 1 shows the film in cross section.
  • Figure 2 shows a possible process for manufacturing the film.
  • Figure 3 shows a joint between parts of the core.
  • A plastic film, for example polystyrene
  • the finished film consists of two layers: One plastic film, for example polystyrene, and a ferromagnetic layer of for example iron carbonyl, i.e. pure iron, which is made by heating iron pentacarbonyl to 200 degrees C.
  • One plastic film for example polystyrene
  • a ferromagnetic layer of for example iron carbonyl i.e. pure iron, which is made by heating iron pentacarbonyl to 200 degrees C.
  • the plastic layer can have a thickness of 5 ⁇ m and the ferromagnetic layer 10 ⁇ m. Thereby the filling factor of the transformer becames approximately 66%. Today the corresponding figure is approximately 85% but observe that the core can be made much smaller thanks to the higher permeability. According to figure 2 the steps in a possible manufacturing process is as follows:
  • the crystal lattice strives to orientate itself so that the easy magnetization directions, which coincide with the crystal directions, become parallel with the applied magnetic field.
  • Purified iron can be applied electrolytically on the plastic film.
  • a thin layer of an electrically conducting material for example aluminum or zinc, can first be applied on the polymer film (compare with the manufacturing of films for capacitors) after which purified iron is applied electrolytically as above.
  • a thin layer of iron carbonyl can first be applied on the polymer film as above, after which purified iron is applied electrolytically.
  • An alternative is to apply purified iron electrolytically on a polymer film with an electrically conducting layer (e.g. lead) which is then melted and/or pulled away and substituted with a new electrically insulating plastic film.
  • an electrically conducting layer e.g. lead
  • Purified iron can also be sprayed in a melted state on a teflon film.
  • the crystal direction can also in all these cases be orientated by a magnetic field during the crystallization as above.
  • the roll with the finished film can be cut diagonally to form joints between the parts of the core in the transformer.
  • the cross-section should be sheared, i.e. the end surface folded to one side with the metal surface outwards in order to give contact metal to metal.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Soft Magnetic Materials (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

A core for an electromagnet is made by applying a thin coating of iron on a thin substrate, i.e. a film, of a polymer. The coated film is formed, e.g. wound, to a core. The iron coating is applied by an iron carbonyl process or electrolytically or by spraying. The core is used in transformers or dynamo-electric machines.

Description

1. TITLE: Manufacturing of ferromagnetic film for transformer and motor cores.
2. The invention relates to the manufacturing of a film according to the precharacterizing part of claim 1 which consists of a ferromagnetic thin film for the manufacturing of magnetic cores for transformers and electrical rotating machines.
3. It is well known that magnetic cores for transformers and electrical rotating machines are manufactured today with thin (approximately 0,25 - 0,5 mm) silicon alloyed iron plates with an intermediate insulation to reduce the losses due to eddy currents . The plates are placed together to form a core. To reduce the losses due to the hysteresis, the plate is normally manufactured with an orientation of the directions of the crystals .
However, the manufacturing of the core is time-consuming, the cores are heavy and the magnetic permeability is relatively low in normal silicon alloyed plates.
4. The purpose of the invention is to achieve a very thin and flexible ferromagnetic film with a high magnetic permeability and orientated crystal direction for the manufacturing of transformer and motor cores.
The advantages are then:
* Thanks to the thin layers (for example 10 μm) the losses due to eddy currents can be kept very low. Since the losses due to eddy currents are proportional to the square of the thickness of the plate, they are reduced 625 times if the thickness is 10 μm instead of the normal 0,25 mm. If the material does not contain silicon, the difference is reduced somewhat (approximately 6 times) .
* High magnetic permeability increases the inductance and therefore the number of winding turns and the height of the core can be reduced and therefore also the size and wheight of the transformer.
(Higher inductance increases the magnetic energy that can be transferred between the primary and secondary windings, that is the purpose of a iron core.)
The initial permeability for silicon alloyed orientated plate is 1.500 Vs/Am whereas it is for example for iron carbonyl 10.560 Vs/Am.
* The flexible film makes the manufacturing of the core much simpler and quicker - the parts of the core can simply be rolled together or transported to the transformer manufacturer as prefabricated rolls and therefore the productivity is increased and the transformer cost is reduced. The cost' of the film can be kept low through cheap raw material and a continuous manufacturing process. * Lower noise level thanks to higher mechanical damping.
* Cheaper refrigerating equipment and higher efficiency thanks to lower losses.
5. The solution is described in the precharacterizing part of claim 1.
6. One possible design of the invention is shown schematically in the attached drawing.
Figure 1 shows the film in cross section.
Figure 2 shows a possible process for manufacturing the film.
Figure 3 shows a joint between parts of the core.
Legend of figure 1:
A = plastic film, for example polystyrene
B = ferromagnetic layer
Legend of figure 2 :
C = roll with the plastic film
D = application of iron pentacarbonyl, formula: Fe(CO)5
E = heating up till 200 degrees C
F = orientation of the crystal direction by a strong magnetic field
G = cooling
H = rolling up the finished magnetic film
7. According to figure 1, the finished film consists of two layers: One plastic film, for example polystyrene, and a ferromagnetic layer of for example iron carbonyl, i.e. pure iron, which is made by heating iron pentacarbonyl to 200 degrees C.
The plastic layer can have a thickness of 5 μm and the ferromagnetic layer 10 μm. Thereby the filling factor of the transformer becames approximately 66%. Today the corresponding figure is approximately 85% but observe that the core can be made much smaller thanks to the higher permeability. According to figure 2 the steps in a possible manufacturing process is as follows:
Rolling off the plastic film, application of the iron pentacarbonyl on the film in a layer of the desired thickness (as a powder in a cooled state, melting point -20 degrees C, or as a liquid film for finer layers) heating under which carbon monoxide escapes and the iron pentacarbonyl is transformed into pure iron (a common technical method) which is stuck on the, by the heating softened, plastic layer, orientation of the crystal direction during the crystallization of the iron through a strong and orientated magnetic field, cooling and finally forming a roll of the finished product. During the process, the plastic film can be placed on a wire.
When the solidifying material is exposed to the magnetic field, the crystal lattice strives to orientate itself so that the easy magnetization directions, which coincide with the crystal directions, become parallel with the applied magnetic field.
Observe that polystyrene, like most polymers, can withstand a short heating. Observe also that pure iron is plastically workable with a low hardness. Thus, the iron layer does not crack during the handling of the finished film.
Alternative materials and methods :
Purified iron (i.e. iron with a purity of > 99,95 % Fe, μr max = 180.000, compare with orientated silicon plate 30.000) can be applied electrolytically on the plastic film.
A thin layer of an electrically conducting material, for example aluminum or zinc, can first be applied on the polymer film (compare with the manufacturing of films for capacitors) after which purified iron is applied electrolytically as above.
As an alternative, a thin layer of iron carbonyl can first be applied on the polymer film as above, after which purified iron is applied electrolytically.
An alternative is to apply purified iron electrolytically on a polymer film with an electrically conducting layer (e.g. lead) which is then melted and/or pulled away and substituted with a new electrically insulating plastic film.
Purified iron can also be sprayed in a melted state on a teflon film.
The crystal direction can also in all these cases be orientated by a magnetic field during the crystallization as above. The roll with the finished film can be cut diagonally to form joints between the parts of the core in the transformer. To achieve a good magnetical contact in the joints and to close the magnetic field, the cross-section should be sheared, i.e. the end surface folded to one side with the metal surface outwards in order to give contact metal to metal.
See figure 3.

Claims

8. Claims
1. Manufacturing of a ferromagnetic film consisting of two types of thin layers (around 10 μm) where one of the layers consists of an electrically insulating polymer and the other layer consists of pure iron with a soft magnetic characteristic (low remanence) , high magnetic permeability and orientated crystals, for the manufacturing of magnetic cores for transformers and electrical rotating machines. c h a r a c t e r i z e d i n that the film is manufactured by applying pure iron on a polymer film
2. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that the film is manufactured by applying a layer of iron pentacarbonyl (as a powder or a liquid) on the polymer film which is then heated at which iron carbonyl (= pure iron) is formed and stuck on the polymer surface.
3. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that the film is manufactured by applying electrolytically purified iron on the plastic film i.e. iron with a purity of > 99,95 % Fe
4. Ferromagnetic film according to claims 1 and 3 c h a r a c t e r i z e d i n that a thin layer of an electrically conducting material, for example aluminum or zinc, is applied on the polymer film after which purified iron is applied electrolytically according to claim 3
5. Ferromagnetic film according to claims 1, 2 and 3 c h a r a c t e r i z e d i n that a thin layer of iron carbonyl is applied on the polymer film according to claim 2 after which purified iron is applied electrolytically according to claim 3
6. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that purified iron is applied electrolytically on a polymer film with an electrically conducting layer (for example lead) which is then melted and/or pulled away and substituted with a new electrically insulating plastic film.
7. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that the direction of the crystals of the ferromagnetic material is orientated by a magnetic field during the crystallization during the manufacturing process
8. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that the finished film is rolled and can be applied in an transformer or motor directly in this rolled shape.
9. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that the roll is cut diagonally to form joints between the parts of the core and that the cross-section is sheared to close the magnetic field between the parts of the core, i.e. the end surface is folded to one side with the metal surface outwards in order to give contact metal to metal.
10. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that the film is manufactured by spraying melted purified iron on a teflon film AMENDED CLAIMS
[received by the International Bureau on 03 January 1996 (03.01.96); original claims 1-5 amended; remaining claims unchanged (1 page)]
1. Manufacturing of a ferromagnetic film consisting of two types of thin layers (around 10 μm) where one of the layers consists of an electrically insulating plastic film and the other layer consists of a continuous and orientated crystal lattice of pure iron with a soft magnetic characteristic (low remanence) and a high magnetic permeability for the manufacturing of magnetic cores for transformers and electrical rotating machines. c h a r a c t e r i z e d i n that the film is manufactured by chemical ly or electrolytically forming a continuous crystal lattice of αιe iron on a plastic film.
2. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that the film is manufactured by applying a layer of iron pentacarbonyl as liquid on the plastic film which is then heated, at which a thin continuous crystal lattice of iron carbonyl (= pure iron) is formed and stuck on the surface on the plastic film.
3. Ferromagnetic film according to claims 1 and 2 c h a r a c t e r i z e d i n that a thin continuous crystal lattice of iron carbonyl is applied on the plastic film according to claim 2, after which purified iron, i.e. iron with a purity of > 99,95 % Fe, is applied electrolytically on the film.
4. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that purified iron is applied electrolytically on a film with an electrically conducting layer (for example lead) which is then melted away and substituted with a new electrically insulating plastic film.
5. Ferromagnetic film according to claim 1 c h a r a c t e r i z e d i n that the direction of the continuous crystal lattice of the iron is orientated by a magnetic field during the crystallization during the manufacturing process
PCT/SE1995/000911 1994-08-12 1995-08-08 Manufacturing of ferromagnetic film for transformer and motor cores WO1996005603A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
SE9700455A SE9700455L (en) 1994-08-12 1997-02-11 Manufacture of ferromagnetic foil for transformer and motor cores

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE9402704-2 1994-08-12
SE9402704A SE9402704D0 (en) 1994-08-12 1994-08-12 Ferromagnetic foil for transformer and motor cores

Publications (1)

Publication Number Publication Date
WO1996005603A1 true WO1996005603A1 (en) 1996-02-22

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WO (1) WO1996005603A1 (en)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1267546A (en) * 1968-07-12 1972-03-22 Leonardus Franciscus Van Berg Inductive winding
DE2914123A1 (en) * 1979-04-07 1980-10-23 Philips Patentverwaltung Ring core transformer with ribbon core for low frequency duty - uses core material wound round finished coil winding
JPS62179706A (en) * 1986-02-04 1987-08-06 Fujitsu Ltd Manufacture of soft magnetic material
US4790064A (en) * 1985-12-04 1988-12-13 General Electric Company Method of manufacturing an amorphous metal transformer core and coil assembly
EP0367144A2 (en) * 1988-10-31 1990-05-09 Matsushita Electric Industrial Co., Ltd. Laminated magnetic material and method of producing the same
JPH02191310A (en) * 1989-11-07 1990-07-27 Seiko Epson Corp Manufacture of tape-shaped permanent magnet

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1267546A (en) * 1968-07-12 1972-03-22 Leonardus Franciscus Van Berg Inductive winding
DE2914123A1 (en) * 1979-04-07 1980-10-23 Philips Patentverwaltung Ring core transformer with ribbon core for low frequency duty - uses core material wound round finished coil winding
US4790064A (en) * 1985-12-04 1988-12-13 General Electric Company Method of manufacturing an amorphous metal transformer core and coil assembly
JPS62179706A (en) * 1986-02-04 1987-08-06 Fujitsu Ltd Manufacture of soft magnetic material
EP0367144A2 (en) * 1988-10-31 1990-05-09 Matsushita Electric Industrial Co., Ltd. Laminated magnetic material and method of producing the same
JPH02191310A (en) * 1989-11-07 1990-07-27 Seiko Epson Corp Manufacture of tape-shaped permanent magnet

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN, Vol. 12, No. 24, E-576; & JP,A,62 179 706 (FUJITSU LTD), 6 August 1987. *
PATENT ABSTRACTS OF JAPAN, Vol. 14, No. 467, E-989; & JP,A,02 191 310 (SEIKO EPSON CORP), 27 July 1990. *

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