WO2025004891A1 - Matériau magnétique en couches, noyau pour un transformateur et procédé permettant de produire un matériau magnétique en couches - Google Patents

Matériau magnétique en couches, noyau pour un transformateur et procédé permettant de produire un matériau magnétique en couches Download PDF

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WO2025004891A1
WO2025004891A1 PCT/JP2024/021895 JP2024021895W WO2025004891A1 WO 2025004891 A1 WO2025004891 A1 WO 2025004891A1 JP 2024021895 W JP2024021895 W JP 2024021895W WO 2025004891 A1 WO2025004891 A1 WO 2025004891A1
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Prior art keywords
resin
magnetic material
laminated
quenched alloy
magnetic
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English (en)
Japanese (ja)
Inventor
石川湧己
野口伸
相牟田京平
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Proterial Ltd
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Proterial Ltd
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Priority to CN202480041007.XA priority Critical patent/CN121336273A/zh
Priority to JP2024563438A priority patent/JP7687539B1/ja
Publication of WO2025004891A1 publication Critical patent/WO2025004891A1/fr
Anticipated expiration legal-status Critical
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/25—Magnetic cores made from strips or ribbons
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • 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

Definitions

  • the present invention relates to a laminated magnetic material, a transformer core, and a method for manufacturing the laminated magnetic material.
  • thermoplastic resins such as the hot-melt polyester resin described in Patent Document 2 do not provide sufficient heat resistance or long-term reliability. For this reason, a new technology was needed to prevent deterioration of magnetic properties.
  • the present invention aims to provide a laminated magnetic material, a transformer core, and a method for manufacturing the laminated magnetic material, which has excellent heat resistance, is advantageous in ensuring reliability, and maintains excellent magnetic properties.
  • the laminated magnetic material of the present invention is a laminated magnetic material in which Fe-based soft magnetic quenched alloy ribbons are interlayer-bonded with a thermosetting or room temperature curing resin,
  • the resin has a glass transition temperature of 110° C. or less as measured by a differential scanning calorimeter;
  • the peel strength of the laminated magnetic material in a 180° peel test at room temperature is 0.5 gf/mm or more, and the magnetic flux density B80 in a longitudinal magnetic field of 80 A/m is 1.25 T or more. It is a laminated magnetic material.
  • the manufacturing method of the present invention is a manufacturing method of a laminated magnetic material in which Fe-based soft magnetic quenched alloy ribbons are interlayer-bonded with a thermosetting or room temperature curing resin, comprising the steps of: adjusting the magnetic flux density B80 of the soft magnetic quenched alloy ribbon to 1.4 T or more when a magnetic field of 80 A/m is applied in a longitudinal direction; applying the resin, the glass transition temperature of which is 110° C.
  • the peel strength of the laminated magnetic material in a 180° peel test at room temperature is 0.5 gf/mm or more, and the magnetic flux density B80 when a magnetic field of 80 A/m is applied in the longitudinal direction is 1.25 T or more.
  • a method for manufacturing a laminated magnetic material is 0.5 gf/mm or more, and the magnetic flux density B80 when a magnetic field of 80 A/m is applied in the longitudinal direction is 1.25 T or more.
  • the present invention provides a laminated magnetic material that has excellent heat resistance, is advantageous in ensuring reliability, and maintains excellent magnetic properties.
  • FIG. 1 is a schematic perspective view illustrating one embodiment of a laminated magnetic material of the present invention.
  • 1 is a schematic perspective view showing one embodiment of a laminated magnetic material of the present invention in which a resin layer 2 is disposed between two soft magnetic rapidly solidified alloy ribbons 1.
  • FIG. FIG. 2 is a diagram illustrating a test piece for a T-peel test used in an example of the present invention.
  • 1 is a schematic perspective view showing one embodiment of a transformer core of the present invention.
  • the present inventors first used a laminated magnetic material as a basic structure in which Fe-based soft magnetic quenched alloy ribbons were interlayer-bonded with a thermosetting or room temperature curing resin.
  • the Fe-based rapidly spun soft magnetic alloy ribbon is mainly composed of Fe, i.e., contains 50 mass % or more of Fe, and thus can obtain a high magnetic flux density.
  • the rapidly spun soft magnetic alloy ribbon can reduce iron loss.
  • thermosetting or room temperature curing resins can improve the heat resistance, which is a problem with thermoplastic resins such as hot melt type polyester resins.
  • the mere use of a thermosetting or room temperature curing resin is not sufficient to provide satisfactory reliability and magnetic properties. Therefore, a new laminated magnetic material has been found that solves the above problems by adjusting the magnetic properties of the Fe-based soft magnetic quenched alloy ribbon, selecting the resin, and reducing the adhesive stress.
  • the resin used in this embodiment has a glass transition temperature measured by a differential scanning calorimeter of 110° C. or lower. By lowering the glass transition temperature, stress is less likely to remain in the bonding process, and the bonding stress can be reduced. Furthermore, in the laminated magnetic material of this embodiment, the peel strength of the laminated magnetic material in a 180° peel test at room temperature is specified to be 0.5 gf/mm or more, because this is recognized as a necessary characteristic when handling properties, etc. of the laminated magnetic material are taken into consideration.
  • the laminated magnetic material of the present invention achieves a magnetic flux density B80 (hereinafter simply referred to as B80) of 1.25 T or more when a magnetic field of 80 A/m is applied in the longitudinal direction.
  • the laminated magnetic material can achieve a high magnetic flux density while maintaining the necessary peel strength, making it particularly useful as a core for a power distribution transformer.
  • the laminated magnetic material of the present invention has a B80 of 1.39 T or more and an iron loss P CM (hereinafter referred to as P CM14/50 ) of 0.16 W/kg or less at a frequency of 50 Hz and a maximum magnetic flux density of 1.4 T.
  • the PCM14/50 when the laminated magnetic material is evaluated in terms of the soft magnetic quenched alloy ribbons constituting the laminated magnetic material, the PCM14/50 can be set to 0.26 W/kg or less when the B80 is 1.4 T or more. In this way, it is useful to realize a configuration in which the Fe-based soft magnetic quenched alloy ribbons can be arranged without significantly deteriorating the inherent performance of the laminated magnetic material.
  • the resin to be applied is not limited, but it is preferable to use at least one of the following resins: epoxy resin, epoxy-modified silicone resin, and acrylic resin.
  • the epoxy resin may be, for example, a known monofunctional epoxy resin or polyfunctional epoxy resin.
  • modified epoxy resins such as bisphenol A type epoxy resin, bisphenol F type epoxy resin, novolac type epoxy resin, aliphatic type epoxy resin, glycidylamine type epoxy resin, urethane modified epoxy resin, and rubber modified epoxy resin. These epoxy resins may be used alone or in a mixture of two or more types.
  • Epoxy modified silicone resins are preferable because they have an extremely low flexural modulus, making it possible to significantly reduce adhesive stress.
  • the type of epoxy modified silicone resin may be either one in which some of the functional groups of the modified silicone resin have been replaced with epoxy groups, or one in which the epoxy resin and modified silicone are incompatible and phase-separated to form an island structure.
  • Acrylic resins are preferred because they cure quickly, making it possible to shorten the bonding process; some two-part room temperature curing types can cure by contact reaction, meaning that the reaction begins and the resin hardens when the two parts come into contact (honeymoon bonding) even if the two parts are not mixed thoroughly; and there are a wide variety of room temperature curing methods available, such as anaerobic bonding and photocuring bonding, making it easy to optimize the bonding process.
  • the room temperature curable acrylic resin used in the present invention may be a second generation acrylic resin (SGA).
  • SGA is a resin that hardens through graft polymerization of an elastomer and an acrylic monomer, and although it is thermoplastic, it has high heat resistance and is less likely to lose adhesive strength at high temperatures.
  • components of acrylic resin include polyacrylic acid and its copolymers, polyacrylic acid esters and their copolymers, polymethacrylic acid and its copolymers, polymethacrylic acid esters and their copolymers, urethane-acrylic acid copolymers, and styrene-acrylic acid copolymers. These acrylic resins may be used alone or in a mixture of two or more types.
  • the resin can be disposed by adding a step of applying the resin to one or both sides of the soft magnetic quenched alloy ribbon.
  • the method of applying the resin is not particularly limited, but for example, a method of applying the resin by flexographic printing, or a method of preparing an adhesive containing a resin and a solvent, applying the adhesive by a spray or coater, and then evaporating the solvent, etc. can be applied.
  • the soft magnetic quenched alloy ribbons are laminated and the resin is cured, thereby obtaining the laminated magnetic material of the present embodiment.
  • the soft magnetic quenched alloy ribbons are laminated on each other, pressed together with a roller or the like, and then heated as necessary depending on the curing temperature of the resin to cure.
  • an amorphous alloy or a nanocrystalline alloy can be used as the Fe-based soft magnetic quenched alloy ribbon applied to this embodiment.
  • an Fe-Si-B system Si: 0 atomic % to 10 atomic %, B: 10 atomic % to 20 atomic %, the balance being Fe and impurities
  • the soft magnetic quenched alloy ribbon described above can be produced by a single roll method in which a molten alloy is poured onto the cylindrical surface of a casting roll rotating at high speed, and quenched the moment it touches the surface of the casting roll to obtain a continuous ribbon.
  • the cooling rate in this case is very fast, about 10 6 °C/s, and the molten alloy can be made into a ribbon without crystallizing.
  • the alloy is slit to a predetermined width and wound into a coil.
  • the width of the soft magnetic quenched alloy ribbon (hereinafter also referred to as ribbon) is not particularly limited, but may be, for example, 100 mm or more. If the ribbon width is 100 mm or more, a practical distribution transformer core can be suitably manufactured.
  • the ribbon width is more preferably 125 mm or more.
  • the upper limit of the ribbon width is not particularly limited, but for example, if the manufacturing width using the single roll method exceeds 300 mm, a ribbon with a uniform thickness in the width direction may not be obtained, and as a result, the ribbon may become partially embrittled or have a lower B80 due to the non-uniform shape. It is more preferable that the ribbon width is 275 mm or less. It is also possible to slit the ribbon to adjust the width according to the required transformer characteristics.
  • the thickness of the soft magnetic quenched alloy ribbon is preferably 10 ⁇ m or more and 50 ⁇ m or less, and more preferably 15 ⁇ m or more and 35 ⁇ m or less. This is because if it is too thin, the mechanical strength is compromised, and if it is too thick, it becomes difficult to obtain an amorphous layer stably.
  • Soft magnetic quenched alloy ribbons have no anisotropy due to the crystal structure, and no grain boundaries that impede the movement of the magnetic domain walls, so they have excellent soft magnetic properties with high magnetic permeability and low loss while still having high magnetic flux density.
  • Soft magnetic quenched alloy ribbons by themselves preferably have a B80 of 1.4 T or more, and preferably 1.48 T or more.
  • the soft magnetic quenched alloy ribbon is effective as a ribbon for transformers if it has an easy magnetization direction in the ribbon longitudinal direction. Therefore, in the manufacturing method of this embodiment, the process for obtaining the soft magnetic quenched alloy ribbon described above requires a process for adjusting B80 to 1.4 T or more. Specifically, this process is preferably performed, for example, by a method of performing heat treatment in a tensioned state (tension annealing), a method of performing heat treatment with a magnetic field applied in the ribbon longitudinal direction, or a method of performing heat treatment with a magnetic field applied in the ribbon longitudinal direction while being tensioned.
  • the B80 is adjusted to 1.48 T or more.
  • the thickness of the resin layer is preferably 5 ⁇ m or less, more preferably 3.0 ⁇ m or less, and even more preferably 2.0 ⁇ m or less.
  • the resin layer is too thin, it may not be possible to exhibit sufficient adhesive strength, so it is preferably 1 ⁇ m or more, and more preferably 1.5 ⁇ m or more.
  • the adhesive stress ⁇ [MPa] expressed by the following formula is 2.5 [MPa] or less. More preferably, the adhesive stress ⁇ is 0.4 [MPa] or less.
  • This adhesive stress disrupts the magnetic domain structure of the soft magnetic quenched alloy ribbon, degrading the magnetic properties of the soft magnetic quenched alloy ribbon.
  • phenomena such as increased iron loss and reduced magnetic flux density when a specified magnetic field is applied occur.
  • An increase in core iron loss leads to a decrease in transformer efficiency, and a decrease in magnetic flux density when a specified magnetic field is applied causes a problem of increased noise generated when the transformer is excited. Therefore, when using soft magnetic quenched alloy ribbon as a transformer core, it is effective to control the adhesive stress generated in the soft magnetic quenched alloy ribbon to be as small as possible.
  • Fig. 1 is a schematic perspective view for explaining one embodiment of the laminated magnetic material of the present embodiment.
  • Fig. 1(a) is a schematic perspective view showing one embodiment of the laminated magnetic material, and does not necessarily correspond to the actual dimensions.
  • Fig. 1(a) shows an example in which the soft magnetic quenched alloy ribbon has three layers, but in this embodiment, the number of layers is not limited.
  • the laminated magnetic material 11 of this embodiment includes a plurality of soft magnetic quenched alloy ribbons 1 and a resin layer 2 arranged between the plurality of soft magnetic quenched alloy ribbons 1.
  • FIG. 1(b) is a schematic perspective view showing one embodiment of the soft magnetic quenched alloy ribbon 1, which has two opposing main surfaces 1a and 1b.
  • FIG. 2 is a schematic perspective view showing a laminated magnetic material 12 in which a resin layer 2 is disposed between two soft magnetic quenched alloy ribbons 1.
  • the resin layer 2 is disposed on at least one of the main surfaces 1a, 1b of the soft magnetic quenched alloy ribbon 1.
  • the resin layer 2 may be disposed on each of the two main surfaces 1a, 1b of the soft magnetic quenched alloy ribbon 1.
  • the resin layer 2 may be disposed over the entire main surfaces 1a, 1b, or may be provided in a predetermined pattern, such as stripes or dots, on the main surfaces 1a, 1b including areas where the resin layer 2 is disposed and areas where the resin layer 2 is not disposed.
  • Adhesive stress ⁇ The adhesive stress ⁇ [MPa] can be evaluated by the above-mentioned (Equation 1).
  • Equation 1 a method for deriving each factor for calculating the adhesive stress ⁇ will be described.
  • the flexural modulus ⁇ of the resin cured product is measured by a three-point bending test with reference to JIS K7171:2016.
  • the bending test device is an autograph AGX-100kNV manufactured by Shimadzu Corporation.
  • the test piece is made by pouring the resin into a mold with a rectangular cross section and a strip shape, and curing the resin.
  • the number of test pieces is three for each resin.
  • the distance L between the supports in the three-point bending test is 30 mm.
  • the test speed is 1 mm/min, and the load F [N] applied to the sample and the deflection D [mm] at that time are measured continuously until the bending strain ⁇ derived from the following (Equation 2) exceeds 0.0025.
  • the bending stress ⁇ and bending strain ⁇ are calculated using the following (Equation 2) and (Equation 3), and a stress-strain curve is obtained.
  • a linear regression is performed by the least squares method on the stress curve in the bending strain range 0.0005 ⁇ 0.0025 of the stress-strain curve, and the slope is taken as the bending modulus ⁇ .
  • the measurement is repeated three times for each resin using different test pieces, and the average value is taken as the bending modulus ⁇ of the resin at room temperature.
  • (Math. 2) ⁇ (6 ⁇ T/L 2 ) ⁇ D
  • Math. 3) ⁇ (3 ⁇ F ⁇ L)/(2 ⁇ W ⁇ T 2 )
  • a low flexural modulus ⁇ is effective in reducing the adhesive stress ⁇ .
  • it is effective to use a resin with a low glass transition temperature Tg.
  • the flexural modulus ⁇ is preferably 2600 MPa or less, more preferably 1000 MPa or less, and even more preferably 100 MPa or less.
  • the glass transition temperature Tg is preferably 110°C or less, more preferably 70°C or less, and even more preferably room temperature or lower.
  • thermomechanical analyzer DIL402 manufactured by NETZSCH is used as an apparatus capable of increasing the temperature of a test piece at a constant rate in a constant atmosphere and performing measurements in compression mode.
  • This apparatus has a space in a cylindrical furnace in which a jig on which a sample is set can be placed, and the linear thermal expansion coefficient ⁇ 1 of the sample attached to this jig can be measured.
  • this apparatus requires a sample of 15 mm in length, but it is difficult to form that size with the resin to be measured.
  • the measurement conditions are a temperature rise rate of about 1° C./min and a measurement temperature range of 35° C. to 55° C.
  • the average linear thermal expansion coefficient in the range of 40° C. to 50° C. during the temperature rise process is calculated by the method described in JIS K7197:1991, and this average linear expansion coefficient is used as the linear thermal expansion coefficient ⁇ 1 of the resin.
  • the measurement is repeated three times for each resin using different test pieces, and the average value is used as the linear thermal expansion coefficient ⁇ 1 of the resin.
  • the specific gravity Sg i of the uncured resin and the specific gravity Sg f of the cured resin required for (Equation 4) are measured in accordance with the specific gravity cup method described in JIS K6833-1:2008 and the underwater substitution method described in JIS K7112:1999.
  • the uncured specific gravity of a two-part mixture adhesive is calculated as follows. If the two-part mixture adhesive is made up of parts A and B, the uncured specific gravity Sg of part A and the uncured specific gravity SgB of parts A and B are measured using the specific gravity cup method described in JIS K6833-1:2008.
  • the mixed masses of parts A and B are determined based on the recommended mixing mass ratio of the two-part mixture adhesive, and are calculated according to the following (Equation 5).
  • the thickness h2 of the soft magnetic quenched alloy ribbon is evaluated by calculating the thickness per sheet from the density derived by the underwater displacement method and multiplying it by the number of layers.
  • the glass transition temperature Tg of the cured resin is measured by a differential scanning calorimeter (DSC) using heat flux differential scanning calorimetry with reference to JIS K7121:2012.
  • a measuring device, DSC 3500 Sirius manufactured by NETZSCH, is prepared.
  • An aluminum pan for DSC measurement containing about 10 mg of a cured resin sample is set in this device, and the measurement is performed under an argon atmosphere with a flow rate of 50 ml/min.
  • Temperature scanning is performed as follows. First, the sample is heated from near room temperature to a temperature at least 50°C higher than the expected glass transition temperature Tg of the sample (to 60°C for samples whose glass transition temperature is expected to be below room temperature) at a heating rate of 20°C/min, and then kept constant at that temperature for 10 minutes. Next, the temperature is lowered to -140°C at a heating rate of 20°C/min, and then kept constant at that temperature for 10 minutes. Next, the temperature is raised to 220°C at a heating rate of 20°C/min. The DSC curve measured during this second heating process is used to analyze the glass transition temperature Tg.
  • the glass transition temperature Tg is determined as follows. First, the extrapolated glass transition onset temperature is determined as the temperature at the intersection of a straight line extending the low-temperature side baseline of the stepwise change portion of the glass transition of the DSC curve to the high-temperature side and a tangent drawn at the point where the gradient of the stepwise change portion of the glass transition is maximum. Next, the extrapolated glass transition end temperature is determined as the intersection of a straight line extending the high-temperature side baseline to the low-temperature side and a tangent drawn at the point where the gradient of the stepwise change portion of the glass transition is maximum.
  • the midpoint glass transition temperature is determined as the temperature between the extrapolated glass transition onset temperature and the extrapolated glass transition end temperature, and the midpoint glass transition temperature is determined as the glass transition temperature Tg of the resin.
  • Tg glass transition temperature
  • the space factor SF is calculated from the thickness h1 of the resin in the laminated magnetic material and the thickness h2 of the soft magnetic quenched alloy ribbons in the laminated magnetic material by the following formula.
  • peel strength of the laminated magnetic material at room temperature refers to the peel strength evaluated by a T-peel test among the 180° peel test methods, and is measured in accordance with JIS K6854-3:1999.
  • the device used in the T-peel test is an Autograph AGX-100kNV manufactured by Shimadzu Corporation. A load cell with a capacity of 50N is used.
  • Figure 3 is a diagram explaining the test pieces for the T-peel test used in the examples of this embodiment.
  • a two-layer laminated magnetic material with a minimum length of 200 mm and width of 25 ⁇ 0.5 mm was prepared, and one side (part B: length 50 mm) was peeled off to create a test piece.
  • the number of test pieces was five for each resin.
  • the test is performed at room temperature (23°C) by gripping the tip of part B at 25 mm and pulling in the direction of the arrow in the figure.
  • the peel speed is constant at 100 mm/min, and pulling is continued until the entire adhesive part (part C: length 150 mm) is peeled off.
  • the evaluation range of the measurement results is evaluated in the range excluding the part peeled off at the start of peeling of part C (part E1 : 25 mm) and the part peeled off at the end of peeling (part E2 : 25 mm).
  • the average peel force in this evaluation range is recorded for each test piece.
  • the measurement is repeated five times for different test pieces for each resin, and the average value of the average peel strength of each test piece is taken as the peel strength [gf/mm] at room temperature of the laminated magnetic material using that resin.
  • the peel strength of the laminated magnetic material at 75°C is measured by changing some of the measurement conditions from the peel strength measurement at room temperature described above.
  • the equipment used in the T-peel test is an Autograph AGX-100kNV manufactured by Shimadzu Corporation. A load cell with a capacity of 50N is used. In addition, a thermostatic chamber TCE-N300 manufactured by Shimadzu Corporation is prepared.
  • the test pieces are prepared by preparing a two-layer laminated magnetic material with a minimum length of 200 mm and a width of 25 ⁇ 0.5 mm, and peeling off one side (part B: length 50 mm) to prepare the test piece.
  • the number of test pieces is five for each resin.
  • the test is performed by placing the autograph gripping tool and the test piece in the air atmosphere heated to 75°C in the thermostatic chamber, and measuring.
  • the peel speed is a constant speed of 100 mm/min, and the adhesive part (part C: length 72.5 mm) is pulled until it peels off.
  • the evaluation range of the measurement results is evaluated in the range excluding the part peeled off at the start of peeling of part C (part E1 : 20 mm).
  • the average peel force in this evaluation range is recorded for each test piece. The measurement is repeated five times for different test pieces for each resin, and the average value of the average peel strength of each test piece is taken as the peel strength [gf/mm] at room temperature of the laminated magnetic material using that resin.
  • the magnetic properties are evaluated based on two factors: the evaluation value of the laminated magnetic material, and the evaluation value of the soft magnetic quenched alloy ribbon portion constituting the laminated magnetic material.
  • the magnetic properties are evaluated based on the soft magnetic quenched alloy ribbon portion, the cross-sectional area and the mass of the soft magnetic quenched alloy ribbon portion are used as the basis.
  • the magnetic properties of each were measured with reference to JIS C2556: 2015.
  • the measurement principle was the excitation current method described in JIS C2556: 2015.
  • the measurement device used was an AC magnetic property measuring device, a BH loop analyzer SY8218 manufactured by Iwasaki Electric Co., Ltd., and the amplifier used was a power amplifier SY-5001 manufactured by PMK Co., Ltd.
  • a measurement frame was created and used as a measurement jig based on JIS C2556:2015.
  • the measurement frame is composed of an MnZn ferrite yoke, a resin bobbin, and polyurethane-coated copper wire.
  • the MnZn ferrite yoke is U-shaped, and two yokes of the same shape are used.
  • the sample is sandwiched from above and below using the two MnZn ferrite yokes.
  • the flow of magnetic flux becomes a closed magnetic circuit, preventing the generation of a demagnetizing field in the ribbon and ensuring uniformity in the distribution of the magnetic field applied to the test piece and the magnetic flux distribution within the test piece.
  • a primary winding (excitation coil) (wire diameter 0.5 mm) and a secondary winding (B coil) (wire diameter 0.5 mm) were wound around a resin bobbin with 57 and 100 turns, respectively, using polyurethane-coated copper wire, and a sample was inserted between the bobbins to apply a magnetic field to the ribbon with a bobbin length of 36.2 mm.
  • the background caused by the MnZn ferrite yoke and the gap between the coil and the magnetic material was corrected by connecting a compensation coil between the jig and the BH loop analyzer and adjusting the number of turns of the compensation coil so that the output when no sample was present when a magnetic field of 8000 A/m was applied was zero.
  • FIG. 4 is a perspective view showing one embodiment of a transformer core according to this embodiment.
  • Four laminated magnetic materials 11 are arranged so that their perpendicular end faces in the multiple lamination directions butt against each other to form a rectangular transformer core as a whole.
  • the shape of the transformer core is not limited to this embodiment.
  • a ribbon of 2605HB1M (registered trademark), an amorphous alloy manufactured by Proterial Co., Ltd. by a single roll method, having a length of 120 mm, a width of 25 mm ⁇ 0.5 mm and a thickness of 25 ⁇ m was prepared.
  • a tension of 40 MPa was applied in the longitudinal direction of the ribbon, and tension annealing was performed at 450° C. to impart induced magnetic anisotropy in which the direction corresponds to the easy magnetization direction. This allowed the B80 to be adjusted to 1.55 T. It was also confirmed that the linear thermal expansion coefficient ⁇ 2 of the ribbon alone before bonding was 4.3 ⁇ 10 ⁇ 6 [1/° C.], and that of PCM14/50 was 0.114 W/kg.
  • two of the above-mentioned soft magnetic quenched alloy ribbons were bonded using nine types of resins (for convenience, these resins are referred to as a, b, c, d, e, f, g, h, and i) having various adhesive stresses to produce laminated magnetic materials of Examples 1 to 6 and Comparative Examples 1 to 4.
  • the adhesive was applied to the entire surface of the soft magnetic quenched alloy ribbon using a flexographic printing method, and the other soft magnetic quenched alloy ribbon was placed on top and pressed with a roller. After pressing, the laminate was heated at each curing temperature, or left at room temperature for room temperature curing to be sufficiently cured. Then, the B80 and P CM14/50 of each laminate were measured.
  • the type of resin used in each sample and the adhesion-related factors are shown in Tables 1 and 2.
  • the linear thermal contraction rate ⁇ [%] in Table 2 is calculated by multiplying the value calculated from the linear thermal expansion coefficient ⁇ 1 [10 -6 /°C] of the resin cured product, the linear thermal expansion coefficient ⁇ 2 (4.3 ⁇ 10 -6 /°C) of the soft magnetic quenched alloy ribbon, the curing temperature Ta [°C] of the resin, and room temperature RT (23°C) using the following (Equation 8), by 100.
  • Equation 8 corresponds to some of the terms in (Equation 1), which is the formula for the adhesive stress ⁇ .
  • (Math. 8) ⁇ ( ⁇ 1 - ⁇ 2 ) ⁇ (Ta-RT)
  • the adhesive stress ⁇ was calculated based on (Equation 1) from each factor shown in the above table, and the magnetic properties of the sample were measured. The results are shown in Table 3. Table 3 also shows the magnetic properties evaluated for the soft magnetic quenched alloy ribbon portion that constitutes the laminated magnetic material.
  • the B80 and PCM14/50 in the entire laminated magnetic material shown in Table 3 will be described.
  • resins were used in which the glass transition temperature Tg of the cured resin was 110°C or less and the flexural modulus ⁇ of the cured resin was 2600 MPa or less.
  • the adhesive stress ⁇ was 2.5 MPa or less
  • B80 was higher at 1.25 T or more and PCM14/50 was lower at 0.26 W/kg or less.
  • Examples 1 to 3 resins were used that had a glass transition temperature Tg of 50°C or less and a flexural modulus ⁇ of 1000 MPa or less when the resin was cured.
  • Tg glass transition temperature
  • ⁇ flexural modulus
  • the adhesive stress ⁇ was 0.5 MPa or less
  • B80 was very high at 1.4 T or more
  • PCM14/50 was very low at 0.18 W/kg or less.
  • the peel strength of Examples 1 to 6 was 0.5 gf/mm or more at room temperature, and 0.8 gf/mm or more at a high temperature of 75°C.
  • a peel strength of 0.5 gf/mm or more is a strength at which problems such as crumbling during handling do not occur, and a peel strength of 0.8 gf/mm or more is more preferable.
  • Examples 1 to 6 did not show a significant decrease in peel strength at high temperatures, as did Comparative Example 5, which used polyester resin, and the ratio of the peel strength at 75°C to the peel strength at room temperature was 0.4 or more, demonstrating that the material is suitable for practical use.
  • this embodiment can provide an excellent laminated magnetic material that has excellent heat resistance, maintains a high magnetic flux density, and has low iron loss, a transformer core, and a method for manufacturing the laminated magnetic material.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne : un matériau magnétique en couches qui est avantageux en ce qu'il assure une résistance à la chaleur et une fiabilité tout en conservant d'excellentes propriétés magnétiques ; un noyau pour un transformateur ; et un procédé permettant de produire un matériau magnétique en couches.　Dans le matériau magnétique en couches, un ruban d'alliage trempé magnétique doux à base de Fe est lié entre des couches à l'aide d'une résine thermodurcissable ou d'une résine qui est durcissable à température normale. Le matériau magnétique en couches est caractérisé par : la résine présentant une température de transition vitreuse inférieure ou égale à 110 °C, telle que mesurée à l'aide d'un calorimètre à balayage différentiel ; et présentant une résistance au pelage supérieure ou égale à 0,5 gf/mm dans un procédé de test de pelage à 180° effectué à température ambiante, et une densité de flux magnétique B80 supérieure ou égale à 1,25 T dans un champ magnétique de 80 A/m dans la direction longitudinale.
PCT/JP2024/021895 2023-06-27 2024-06-17 Matériau magnétique en couches, noyau pour un transformateur et procédé permettant de produire un matériau magnétique en couches Ceased WO2025004891A1 (fr)

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CN202480041007.XA CN121336273A (zh) 2023-06-27 2024-06-17 层叠磁性材、变压器用芯子、及层叠磁性材的制造方法
JP2024563438A JP7687539B1 (ja) 2023-06-27 2024-06-17 積層磁性材、トランス用コア、および積層磁性材の製造方法

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004070080A1 (fr) * 2003-02-03 2004-08-19 Nippon Steel Corporation Feuille ou bande d'acier magnetique plane enroulee a surface de fixation revetue
WO2019087932A1 (fr) * 2017-10-31 2019-05-09 日立金属株式会社 Matériau magnétique, matériau magnétique stratifié, paquet stratifié, et noyau stratifié utilisant un matériau magnétique, et procédé de production de matériau magnétique
JP2021154732A (ja) * 2020-03-25 2021-10-07 日立金属株式会社 軟磁性合金薄帯の積層体の製造方法

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023120730A1 (fr) * 2021-12-24 2023-06-29 日立金属株式会社 Matériau magnétique stratifié, noyau magnétique et procédé de production de matériau magnétique stratifié

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004070080A1 (fr) * 2003-02-03 2004-08-19 Nippon Steel Corporation Feuille ou bande d'acier magnetique plane enroulee a surface de fixation revetue
WO2019087932A1 (fr) * 2017-10-31 2019-05-09 日立金属株式会社 Matériau magnétique, matériau magnétique stratifié, paquet stratifié, et noyau stratifié utilisant un matériau magnétique, et procédé de production de matériau magnétique
JP2021154732A (ja) * 2020-03-25 2021-10-07 日立金属株式会社 軟磁性合金薄帯の積層体の製造方法

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