Method for manufacturing amorphous alloy ribbon with V-shaped indentation, and amorphous alloy ribbon

Abstract

The invention relates to the technical field of amorphous alloy material processing, in particular to a manufacturing method of a V-shaped nick amorphous alloy ribbon and the amorphous alloy ribbon, the manufacturing method of the V-shaped nick amorphous alloy ribbon provided by the embodiment of the invention comprises the following steps: forming nicks on a smooth amorphous alloy ribbon by using a knife roll; wherein the knife roll is provided with a cylindrical main body, and a V-shaped blade part is arranged on the peripheral surface of the cylindrical main body in a protruding manner; during the nicking operation, the knife roll presses against the amorphous alloy strip and rotates along the advancing direction of the amorphous alloy strip to obtain an amorphous alloy thin strip with V-shaped nicks on the surface; according to the manufacturing method of the amorphous alloy thin strip with the V-shaped nicks, transverse deviation of the thin strip can be effectively prevented in the nicking machining process, the accuracy and consistency of nicking positions are ensured, meanwhile, the surface quality is improved, and the comprehensive performance and production stability of products are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of amorphous alloy material processing, and in particular to a method for manufacturing a V-shaped notched amorphous alloy thin strip and the amorphous alloy thin strip. Background Art

[0002] Amorphous alloy ribbon, a functional material with excellent soft magnetic properties, is widely used in electromagnetic devices such as transformers, inductors, and motors. Its unique amorphous structure imparts excellent properties such as high magnetic permeability, low coercivity, and low iron loss, making it an ideal material for manufacturing high-efficiency, energy-saving electromagnetic devices.

[0003] However, practical applications of amorphous alloy ribbons face a key technical challenge: how to effectively reduce the material's iron loss while maintaining excellent surface quality. Iron loss is a key performance metric for soft magnetic materials, directly impacting the efficiency and heat generation characteristics of electromagnetic devices. To reduce this iron loss, the industry generally employs a method called notching the ribbon surface to refine the magnetic domain structure and block the propagation paths of eddy currents.

[0004] Currently, the main methods for scoring amorphous alloy ribbons are mechanical scoring and laser scoring. While laser scoring offers high precision, the thermal effects of the laser can damage the amorphous structure around the scoring, forming a heat-affected zone (HAZ), which can degrade the material's magnetic properties. Furthermore, the high cost of the equipment makes large-scale industrial application difficult. Therefore, mechanical scoring remains the mainstream technology.

[0005] An existing Chinese invention patent, CN119790178A, discloses a low-loss amorphous alloy ribbon and its manufacturing equipment and method. The patent uses a spiral cutter roller to mechanically score the surface of the amorphous ribbon, forming traces that refine the magnetic domains. However, in actual production, due to the spiral cutter roller, the ribbon is continuously subjected to lateral forces during the scoring process. Once the tension decreases or the travel speed is too fast, the lateral friction between the ribbon and the anvil decreases, causing the ribbon to shift to one side. This results in unstable scoring morphology and can even lead to direct coiling and ribbon breakage, affecting production efficiency. Summary of the Invention

[0006] The present invention provides a method for manufacturing a V-shaped notched amorphous alloy strip and an amorphous alloy strip. The method for manufacturing a V-shaped notched amorphous alloy strip can effectively prevent the lateral deviation of the strip during the notching process, ensure the accuracy and consistency of the notching position, and at the same time improve the surface quality, thereby enhancing the comprehensive performance and production stability of the product.

[0007] In the first aspect, an embodiment of the present invention provides a method for manufacturing a V-shaped notched amorphous alloy strip, comprising: using a knife roller to form notches on a smooth amorphous alloy strip; wherein the knife roller has a cylindrical main body, and a V-shaped blade portion is protrudingly provided on the outer peripheral surface of the cylindrical main body; during the notching operation, the knife roller presses against the amorphous alloy strip and rotates along the traveling direction of the amorphous alloy strip to obtain an amorphous alloy strip with a V-shaped notch on the surface.

[0008] In a possible implementation, the V-shaped blade portion includes two intersecting straight blade segments, and the two straight blade segments are symmetrically arranged with respect to a radial section passing through the intersection of the two straight blade segments.

[0009] In a possible implementation, the blade angle of the V-shaped blade is in the range of 15°-45°.

[0010] In a possible implementation, the two straight edge segments form a first inflection point at the intersection, and the distance a between the first inflection point and the midpoint of the length direction of the knife roller satisfies: a≤b*40%, where b is the length of the knife roller.

[0011] In a possible implementation, a plurality of V-shaped blades are provided, and the plurality of V-shaped blades are spaced apart along the circumference of the cylindrical body.

[0012] In a possible implementation, the knife roller is provided with a heating device, and the heating temperature of the V-shaped blade is greater than the ductile-brittle transition temperature of the amorphous alloy strip and lower than the crystallization temperature of the amorphous alloy strip.

[0013] In a possible implementation, the heating temperature of the V-shaped blade is in the range of 50°C-350°C.

[0014] In one possible implementation, during the scoring operation, the pressure between the V-shaped blade and the amorphous alloy strip is in the range of 0.1-1 MPa / cm².

[0015] In a second aspect, an embodiment of the present invention provides an amorphous alloy ribbon having a V-shaped notch on its surface.

[0016] In a possible implementation, the cross section of the V-shaped notch is a stepped structure whose width increases toward the opening direction.

[0017] In a possible implementation, the V-shaped notch includes two intersecting straight line notch segments, and the two straight line notch segments are symmetrically arranged along the length direction of the amorphous alloy ribbon.

[0018] In a possible implementation, the included angle between the two straight scoring segments is 90°-180°.

[0019] In one possible implementation, two straight line notch segments form a second inflection point at their intersection, and a distance c between the second inflection point and the center line of the amorphous alloy strip in the width direction satisfies: c≤d*20%, where d is the width of the amorphous alloy strip.

[0020] In a possible implementation, the height of the protrusions on both sides of the V-shaped notch is less than 0.5 μm.

[0021] In a possible implementation, the V-shaped notches are spaced apart along the length direction of the amorphous alloy strip, and the number of intersections between any straight line along the width direction of the amorphous alloy strip and the V-shaped notches is 2-6.

[0022] In a possible implementation, the straight line scoring segment is in the form of a dot, a line, or a combination of a dot and a line.

[0023] The method for manufacturing amorphous alloy thin strips with V-shaped notches provided by the present invention fundamentally solves the key technical problem of lateral deviation of thin strips in the background technology by adopting a knife roller with a V-shaped blade to replace the traditional straight blade, and rotating the knife roller along the direction of travel of the amorphous alloy strip, thereby achieving the beneficial effects of stable positioning of the thin strip and high-quality notching during the notching process. Specifically, the unique geometric structure of the V-shaped blade enables it to always maintain contact with the surface of the strip at at least two points on both sides of the inflection point when in contact with the amorphous alloy strip. This multi-point contact method is essentially different from the linear contact method of the traditional straight blade. When the knife roller rotates, the geometric shape of the V-shaped blade naturally generates symmetrical lateral forces, forming a pulling force on both sides of the strip. This pulling force has a mutually restrictive effect on the deviation of the strip to any side. When the strip tends to deviate to the left, the contact point on the right side of the V-shaped blade exerts a greater restraining force due to geometric constraints, pulling the strip back to the center position. Conversely, when the strip deviates to the right, the contact point on the left side performs the same corrective action. This geometrically based automatic balancing mechanism, unlike the traditional linear blade's limitation of providing only unidirectional force, effectively prevents lateral deviation of the strip during processing, ensuring accurate and consistent scoring. Compared to traditional solutions that rely on complex additional guides, the V-shaped blade of the present invention inherently performs the strip positioning function, achieving high-precision lateral position control without the need for additional guides. This integrated design not only simplifies the equipment structure and reduces manufacturing costs, but also improves processing accuracy and production efficiency. Furthermore, the V-shaped blade's automatic balancing mechanism responds quickly, capable of correcting even minor positional deviations in real time. This ensures stable processing quality even during high-speed continuous production, providing reliable technical support for large-scale industrial production. This solves the technical challenges of unstable product quality and low production efficiency caused by lateral deviation of thin strips in traditional linear blade scoring technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the present invention or the prior art, a brief introduction is given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0025] Figure 1 It is a schematic diagram of the three-dimensional structure of a knife roller provided by the present invention.

[0026] Figure 2 It is a schematic diagram of the planar structure of a knife roller provided by the present invention.

[0027] Figure 3 It is a structural schematic diagram of a knife roller provided by the present invention from an axial perspective.

[0028] Figure 4 It is a schematic diagram of the cross-sectional structure of a V-shaped blade provided by the present invention.

[0029] Figure 5 This is a structural schematic diagram of a knife roller provided by the present invention when the first inflection point is located at the center line.

[0030] Figure 6 This is a structural schematic diagram of a knife roller provided by the present invention when the first inflection point is located on one side of the center line.

[0031] Figure 7 It is a schematic diagram of the planar structure of an amorphous alloy ribbon provided by the present invention.

[0032] Figure 8 This is a schematic structural diagram of an amorphous alloy ribbon provided by the present invention when the second inflection point is located on one side of the center line.

[0033] Figure 9 It is a schematic diagram of the cross-sectional structure of a V-shaped notch provided by the present invention.

[0034] Figure 10 It is a schematic diagram of the cross-sectional structure of another V-shaped notch provided by the present invention.

[0035] Figure 11 It is a schematic diagram of the structure of notches and protrusions in the prior art.

[0036] Figure 12 This is another structural diagram of notches and protrusions in the prior art Reference numerals: 1. Cutter roller; 11. Cylindrical body; 12. V-shaped blade; 121. Straight blade segment; 122. First inflection point; 2. Amorphous alloy ribbon; 21. V-shaped notch; 211. Straight notch segment; 212. Second inflection point. DETAILED DESCRIPTION

[0037] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0038] The following combination Figure 1-6 A method for manufacturing a V-notched amorphous alloy ribbon provided by an embodiment of the present invention includes: Using a knife roller 1 to form a notch on the smooth amorphous alloy strip; The knife roller 1 has a cylindrical main body 11, and a V-shaped blade portion is protrudingly provided on the outer circumference of the cylindrical main body 11; During the scoring operation, the knife roller 1 is pressed against the amorphous alloy strip and rotates along the traveling direction of the amorphous alloy strip to obtain an amorphous alloy strip 2 with V-shaped scoring 21 on the surface; In the present invention, a cutter roller 1 with a V-shaped blade is used to score a smooth amorphous alloy strip, and the cutter roller 1 is rotated along the direction of travel of the amorphous alloy strip, thereby achieving the beneficial effects of stable strip positioning and high-quality score formation. During the scoring process, the V-shaped blade maintains contact with the strip surface at at least two points on either side of the V-shaped inflection point, generating a pulling force on both sides of the strip. This has the effect of mutually restricting the strip from deflecting to either side, effectively preventing lateral deviation of the strip during processing and ensuring the accuracy and consistency of the score position.

[0039] Specifically, the structural design of the V-shaped blade is such that when it contacts the amorphous alloy strip, the two edges of the blade form contact points with the surface of the strip respectively. These contact points are distributed on both sides of the V-shape. When the knife roller 1 rotates, the geometric shape of the V-shaped blade naturally produces a symmetrical lateral force. When the strip tends to deviate to the left, the contact point on the right side of the V-shaped blade will produce a greater restraining force, pulling the strip back to the center position; conversely, when the strip deviates to the right, the contact point on the left plays the same role. This automatic balancing mechanism ensures that the strip maintains a stable lateral position throughout the scoring process. At the same time, the rotational motion of the knife roller 1 forms a continuous scoring process, and the protruding setting of the V-shaped blade on the outer circumference of the cylindrical body 11 ensures reliable contact and effective scoring between the blade and the strip.

[0040] In a specific embodiment, when processing a 142mm wide amorphous alloy strip, the V-shaped blade roller 1 of the present invention was used for scoring. The lateral deviation of the strip was controlled within ±0.5mm throughout the entire process, while the strip deviation in traditional straight blade processing methods typically reached ±2-3mm. This significant improvement in positioning accuracy directly improved the consistency of the scoring and product quality, resulting in more uniform and stable magnetic properties of the core in subsequent lamination applications.

[0041] Conventional mechanical scoring techniques typically utilize straight blades or blades with simple geometric shapes. These blades only provide unidirectional force when in contact with the strip, failing to form an effective lateral restraint mechanism. During the scoring process, the contact points of the straight blade are distributed along a straight line. When the strip deviates laterally, all contact points move in the same direction, lacking the ability to automatically correct the deviation. Consequently, conventional techniques rely on additional guides or complex control systems to maintain the strip's positional stability, increasing equipment complexity and making it difficult to achieve high-precision position control.

[0042] In the embodiments of the present invention, the unique geometry of the V-shaped blade inherently provides strip positioning, enabling highly precise lateral position control without the need for additional guides. This integrated design not only simplifies the equipment structure and reduces manufacturing costs, but also improves machining accuracy and production efficiency. The V-shaped blade's automatic balancing mechanism ensures stable machining quality even during high-speed continuous production, providing reliable technical support for large-scale industrial production.

[0043] In some embodiments, the V-shaped blade portion includes two intersecting straight blade segments 121 , and the two straight blade segments 121 are symmetrically arranged with respect to a radial cross section passing through the intersection thereof.

[0044] In this invention, by designing the V-shaped blade to include two intersecting straight edge segments 121, and arranging these two segments 121 symmetrically about a radial cross-section through their intersection, the beneficial effects of symmetrical distribution of pulling force and optimized notch geometry are achieved. This symmetrical design ensures that both sides of the V-shaped blade exert equal pulling force on the strip, enhancing the effect of limiting strip deflection. It also ensures the symmetry of the notch geometry and improves the uniformity of magnetic properties.

[0045] Specifically, the V-shaped structure formed by the two intersecting straight blade segments 121 exhibits perfect geometric symmetry. When the blade roller 1 rotates, the two straight blade segments 121 form symmetrical contact lines with the strip surface. This symmetrical arrangement means that the two straight blade segments 121 form equal angles with the direction of travel of the amorphous alloy strip, but in opposite directions. This symmetry ensures that when the strip is disturbed by external forces, the restraining forces generated by the blade segments on both sides are equal in magnitude and opposite in direction, forming a stable force balance. The presence of the intersection further strengthens this restraining effect, making the entire V-shaped blade section act like a precise positioning fixture, firmly restraining the strip in the predetermined position.

[0046] In a specific embodiment, when using a symmetrical V-shaped blade with a 25° angle for notching, testing found that the notch depth consistency on both sides of the strip was within ±2%, while when using an asymmetrical blade, the notch depth difference between the two sides typically exceeded ±8%. This significant improvement in consistency directly affects the magnetic property distribution of the amorphous alloy ribbon 2, making the magnetic permeability and loss characteristics more uniform across the ribbon's width, providing high-quality raw material for the manufacture of high-precision electromagnetic devices.

[0047] While the aforementioned technical solution achieves strip positioning through the V-shaped blade, it still suffers from the drawback of inaccurate blade geometry. If the two cutting edges of the V-shaped blade are asymmetrical or their intersection angles deviate, the restraining force generated on both sides will be unbalanced. While this can still limit strip deviation to a certain extent, the accuracy is limited, and cumulative deviations may occur over long processing times.

[0048] In the embodiments of the present invention, strict symmetrical design requirements eliminate the potential problems caused by geometric asymmetry in the blade section, achieving higher-precision strip positioning and a more stable processing process. The symmetrical linear blade segment 121 design also simplifies the manufacturing process of the cutter roller 1, facilitating the use of precision machining methods to ensure geometric accuracy, thereby improving product consistency and reliability.

[0049] like Figure 4 As shown, in some embodiments, the blade angle of the V-shaped blade portion 12 is in the range of 15°-45°.

[0050] In this invention, by limiting the V-shaped blade's included angle to a range of 15°-45°, the notch forming conditions are optimized and the pulling force effect is maximized. This included angle range ensures that the V-shaped blade is sharp enough to generate effective bidirectional pulling force, while also avoiding the insufficient blade strength caused by too small an angle or the weakened cutting effect caused by too large an angle, thus ensuring stable strip positioning and consistent notch quality.

[0051] Specifically, the setting of the blade angle directly affects the geometric characteristics and mechanical properties of the V-shaped blade. When the angle is 20°, the V-shaped blade presents a relatively sharp shape, has excellent penetration ability and cutting effect, and can form clear notches on the surface of the amorphous alloy strip with less pressure. At the same time, the angle between the two straight blade segments 121 is small enough to make the lateral component of the restraining force larger, providing a strong strip positioning effect. When the angle increases to 30°, although the penetration ability is slightly reduced, the mechanical strength of the blade is significantly improved, and it can withstand greater processing loads, which is suitable for thicker or harder amorphous alloy materials. In the entire range of 15°-45°, the V-shaped blade can maintain good geometric stability and processing performance.

[0052] In a specific embodiment, comparative tests were conducted using V-shaped blades with angles of 15°, 25°, and 35°, respectively. The results showed that although the blade with an angle of 15° had a good cutting effect, the tip of the blade wore out too quickly during continuous processing, affecting the stability of the scoring quality; although the blade with an angle of 35° had good strength, the cutting resistance was large, requiring higher processing pressure, and the strip positioning accuracy was reduced; and the blade with an angle of 25° performed the most balanced in various performance indicators, ensuring both a good cutting effect and sufficient strength and stable positioning performance.

[0053] like Figure 5-6 As shown, in some embodiments, two straight edge segments 121 form a first inflection point 122 at the intersection, and the distance a between the first inflection point 122 and the midpoint of the length direction of the knife roller 1 satisfies: a≤b*40%, where b is the length of the knife roller 1.

[0054] In this invention, by limiting the distance a between the first inflection point 122 formed at the intersection of the two linear blade segments 121 and the longitudinal midpoint of the cutter roller 1 to a≤b*40% (where b is the length of the cutter roller 1), a rational distribution of the V-shaped blade positions and optimized scoring coverage are achieved. This positioning ensures that the V-shaped scoring fully covers the effective width of the strip, avoiding magnetic property differences at the edge. It also facilitates the dynamic balance of the cutter roller 1, reduces vibration during processing, and improves the consistency of scoring quality.

[0055] Specifically, the position of the first inflection point 122 directly determines the distribution position of the V-shaped notch in the width direction of the strip. When the distance a between the first inflection point 122 and the midpoint of the length direction of the knife roller 1 is controlled within 40% of the length b of the knife roller 1, it ensures that the V-shaped notch is mainly distributed in the center area of ​​the strip and its vicinity. This area is the main working area of ​​the strip in actual application and has the highest requirements for the uniformity of magnetic properties. At the same time, this position setting makes the mass distribution of the knife roller 1 relatively uniform during rotation, avoiding the dynamic imbalance problem caused by excessive eccentricity of the blade distribution. The good dynamic balance characteristics of the knife roller 1 ensure smooth operation during high-speed rotation, reduce vibration and noise, and improve processing accuracy.

[0056] In a specific embodiment, for a 200 mm long blade roller 1, setting the first inflection point 122 at 60 mm from the midpoint (i.e., a 30% offset) resulted in a standard deviation of the scoring depth of the processed amorphous alloy ribbon 2 within the effective width range of only 0.8 μm. However, when the first inflection point 122 was set at 100 mm from the midpoint (i.e., a 50% offset), the standard deviation increased to 2.3 μm. This demonstrates the importance of properly positioning the inflection point to ensure consistent scoring quality.

[0057] In the embodiment of the present invention, clear positioning requirements ensure the proper distribution of the V-shaped blades on the cutter roller 1, guaranteeing both effective scoring coverage and maintaining good dynamic balance of the cutter roller 1. This precise position control provides a key guarantee for achieving high-quality, consistent scoring results and also creates conditions for the long-term stable operation of the cutter roller 1.

[0058] Preferably, the distance between the first inflection point 122 and the lengthwise center line of the knife roller 1 accounts for 10% of the length of the knife roller 1 .

[0059] More preferably, the first inflection point 122 is located on the center line of the blade roller 1 in the length direction.

[0060] In some embodiments, a plurality of V-shaped blades 12 are provided, and the plurality of V-shaped blades 12 are spaced apart along the circumference of the cylindrical body 11 .

[0061] In the present invention, multiple V-shaped blades are arranged at intervals on the outer circumference of the cylindrical body 11, achieving continuous and efficient scoring. The spacing of the multiple V-shaped blades ensures that V-shaped scoring can be continuously formed on the strip surface during the rotation of the cutter roller 1, thereby improving production efficiency. At the same time, the multiple blade design disperses the wear of individual blades, extending the service life of the cutter roller 1 and reducing production costs.

[0062] Specifically, multiple V-shaped blades are spaced apart along the circumference of the cylindrical main body 11 to form an evenly distributed blade array. When the knife roller 1 rotates, these blades contact the surface of the strip in turn, forming a continuous scoring process. The design of the interval setting ensures that there is enough space between adjacent blades, avoiding mutual interference between the blades, and also facilitates heat dissipation and cleaning during the processing. Each V-shaped blade can independently perform the functions of strip positioning and scoring, and the synergistic effect of multiple blades further enhances the overall stability and reliability. When a blade is slightly worn, the other blades can still maintain normal processing quality, avoiding production interruptions due to single point failures.

[0063] In some embodiments, the knife roller 1 is provided with a heating device, and the heating temperature of the V-shaped blade 12 is greater than the ductile-brittle transition temperature of the amorphous alloy strip and lower than the crystallization temperature of the amorphous alloy strip.

[0064] In the present invention, by providing a heating device on the blade roller 1 and controlling the heating temperature of the V-shaped blade to a range above the ductile-brittle transition temperature of the amorphous alloy strip and below the crystallization temperature of the amorphous alloy strip, a fundamental improvement in the surface quality of the notch and optimization of the notch morphology are achieved. Since the blade temperature is below the crystallization temperature, it does not affect the amorphous structure of the amorphous alloy strip. However, above the ductile-brittle transition temperature, the contact point of the blade becomes brittle due to heat when it contacts the amorphous strip, allowing the desired notch depth to be achieved without excessive pressure, reducing blade wear, reducing the number of blade re-sharpening cycles, and increasing production efficiency.

[0065] Specifically, the setting of the heating device enables the V-shaped blade to maintain a stable heating temperature during operation. When the blade contacts the amorphous alloy strip, the material in the contact area quickly heats up to a preset temperature range. Above the ductile-brittle transition temperature, the molecular structure of the amorphous alloy material changes from a brittle state at room temperature to a state with a certain plasticity, and the ductility and workability of the material are significantly improved. When scoring is performed in this state, the material can undergo plastic flow rather than brittle fracture, avoiding surface defects such as microcracks and material tearing that are common during cold working. At the same time, mechanical scoring by heating the blade of the tool causes significant changes in the morphology of the score. The cross section of the score presents a unique stepped structure, and the upper half of the score cross section shows a significant step-by-step expansion in width. This is because the tip and side of the heated cutting tool will both contact the inner wall of the score. The upper part of the score has a longer contact time, is heated more, and is more brittle. The heated part undergoes brittle cracking after pressure, forming a step-by-step expansion in width.

[0066] In one specific embodiment, the blade heating temperature was set to 350°C (a temperature above the ductile-brittle transition temperature of Fe-based amorphous alloys, approximately 280°C, and below their crystallization temperature, approximately 550°C). The resulting surface protrusion height of the processed amorphous alloy ribbon 2 was only 0.3 μm, a qualitative improvement over the 1.2 μm obtained with cold working. Furthermore, the resulting stepped notch structure almost completely eliminated the protrusions on both sides of conventional notches. For notches of the same width, the lamination factor increased from 0.85 to 0.92, and the iron loss reduction increased from 30% with conventional methods to 49.7%.

[0067] In the related art, when cold working is used, since amorphous alloys are in a brittle state at room temperature, surface defects are easily generated during the scoring process, affecting the subsequent lamination application effect.

[0068] The present invention, through precise temperature control technology, solves the fundamental problem of cold working, not only improving surface quality but also creating a unique stepped scoring structure, achieving a dual improvement in magnetic and mechanical properties. This temperature-controlled processing technology opens up a new technical path for high-end applications of amorphous alloy ribbon 2.

[0069] In some embodiments, the heating temperature of the V-shaped blade portion 12 is in the range of 50°C to 350°C.

[0070] In this invention, by precisely limiting the heating temperature of the V-shaped blade to a range of 50°C to 350°C, the processing technology for different types of amorphous alloys is optimized and the temperature control effect is standardized. This temperature range covers the optimal processing window for commonly used amorphous alloys. The lower limit of 200°C corresponds to the ductile-brittle transition temperature of most iron-based amorphous alloys, ensuring sufficient plasticity. The upper limit of 550°C is close to but below the crystallization temperature of typical amorphous alloys, avoiding the destruction of the amorphous structure, ensuring the stable formation of the stepped notch morphology, and consistent processing results.

[0071] Specifically, the temperature range of 50℃-350℃ has been determined through a large number of material tests and process verifications, and can adapt to amorphous alloy materials of different compositions and thicknesses. For Fe-Si-B amorphous alloys, the ductile-brittle transition temperature is usually between 220-280℃, and the best results can be achieved by processing within the range of 100-200℃. For Fe-Ni-P amorphous alloys, the phase transition temperature is slightly different, but it is still within the coverage range of 50℃-350℃. Precise control of temperature not only affects the processing properties of the material, but also directly determines the morphological characteristics of the notch. At lower temperatures, the plasticity of the material is limited, and the formed stepped structure is not obvious enough; at higher temperatures, the material is too softened, which may cause the notch shape to be unclear or excessive deformation to occur.

[0072] In a specific embodiment, notching tests were conducted on a 25μm-thick Fe78Si9B13 amorphous alloy ribbon 2 at heating temperatures of 150°C, 250°C, 350°C, and 450°C. The results showed that the ideal step-shaped notch morphology was achieved within the 100°C-300°C range, with surface protrusion heights controlled between 0.2 and 0.4μm and notch depth uniformity within ±5%. At 250°C, while surface tearing was avoided, the step-shaped features were less pronounced. At 350°C, slight oversoftening of the notch edges was observed.

[0073] Preferably, the crystallization temperature of common iron-based amorphous strip is below 350°C, and the ductile-brittle transition temperature is around 200°C. During scoring, the blade temperature is between 100°C and 450°C. The ductile-brittle transition is actually caused by the cumulative heat applied to the strip. Therefore, the strip can become brittle by either a long period of low temperature or a short period of high temperature. This is further limited to 50°C-350°C.

[0074] More preferably, the crystallization temperature of the amorphous alloy strip is generally between 350°C. Therefore, we further limit the temperature of the blade to 100°C-300°C.

[0075] In some embodiments, during the scoring operation, a pressure between the V-shaped blade and the amorphous alloy ribbon is in the range of 0.1-1 MPa / cm².

[0076] In this invention, by controlling the pressure between the V-shaped blade and the amorphous alloy strip during the scoring operation within the range of 0.1-1 MPa / cm², precise control of the scoring depth and a stable processing process are achieved. This pressure range enables the ideal scoring depth to be achieved with minimal pressure under heating conditions, reducing blade wear and improving processing efficiency. It also ensures the stable formation of the stepped scoring structure and avoids damage to the strip caused by excessive pressure.

[0077] Specifically, precise control of pressure is a key process parameter for achieving high-quality scoring. The lower limit pressure of 0.1MPa / cm² ensures that the blade can effectively penetrate the oxide layer and impurity layer on the surface of the strip to form a clear scoring profile. Under heating conditions, since the material is in a plastic state, this pressure is sufficient to allow the blade to penetrate deep into the material to form the required scoring depth. The upper limit pressure of 1MPa / cm² prevents damage to the strip caused by excessive pressure, and avoids problems such as excessive scoring, material perforation, or edge tearing. Within this pressure range, the V-shaped blade can form progressive plastic deformation in the material, which is conducive to the formation of a stepped structure. At the same time, moderate pressure is also conducive to extending the service life of the blade and reducing maintenance costs caused by excessive wear.

[0078] In a specific embodiment, notching tests were conducted at a heating temperature of 350°C using pressures of 0.05 MPa / cm², 0.3 MPa / cm², 0.8 MPa / cm², and 1.5 MPa / cm², respectively. The results showed that a pressure of 0.05 MPa / cm² failed to form a notch of sufficient depth, resulting in limited magnetic effect. While a pressure of 1.5 MPa / cm² was able to form a deeper notch, it resulted in microcracks at the edges of the strip, affecting product quality. Pressures of 0.3 MPa / cm² and 0.8 MPa / cm² both achieved ideal notching results, with notch depths of 8 μm and 12 μm, respectively, and excellent surface quality with distinct step-like features.

[0079] like Figure 7-10 As shown, an embodiment of the present invention provides an amorphous alloy ribbon. The surface of the amorphous alloy ribbon 2 has a V-shaped notch. The cross section of the V-shaped notch is a stepped structure with a width expanding toward the opening direction.

[0080] In the present invention, by forming a stepped V-shaped notch on the surface of the amorphous alloy ribbon 2, with the notch cross-section characterized by increasing width toward the opening, excellent surface quality with no protrusions on either side of the notch is achieved, significantly improving the lamination factor. This stepped structure improves the lamination factor of the iron core produced using it, further reducing losses and excitation power, providing a high-quality material for the manufacture of high-performance electromagnetic devices.

[0081] Specifically, the V-shaped notches with a stepped structure have unique geometric characteristics and functional advantages over traditional simple V-shaped or straight notches. The design of the notch cross-section with an expanded width toward the opening direction forms a multi-level stepped interface. This structure provides a more complex magnetic blocking path in magnetics and can more effectively refine the magnetic domain structure. The stepped interface increases the number and density of magnetic domain walls, improving the blocking effect on magnetic domain propagation. At the same time, the feature of expanding width toward the opening direction forms a gradual stress distribution inside the notch, avoiding stress concentration that may be caused by sharp edges and improving the mechanical reliability of the thin strip. Most importantly, this special notch morphology almost completely eliminates the raised structures on both sides of the traditional notch, making the surface of the thin strip smoother.

[0082] In one specific embodiment, a transformer core fabricated using amorphous alloy ribbon 2 with stepped V-shaped notches achieved a lamination factor of 0.92, up from 0.85 for conventional notched ribbon. This reduced no-load losses by 15% and current by 12%. This performance improvement is primarily attributed to the stepped notches eliminating surface protrusions, reducing air gaps between laminations, and improving magnetic circuit continuity. Furthermore, the magnetic blocking effect of the stepped structure further reduced core losses by 8% compared to conventional notched ribbons.

[0083] Traditional mechanical scoring techniques often produce thin strips with noticeable raised surfaces. These raised surfaces create air gaps during lamination, reducing the lamination factor and impacting the core's overall performance. While laser scoring can avoid these raised surfaces, the presence of a heat-affected zone (HAZ) also affects material performance.

[0084] In the embodiments of the present invention, a unique stepped scoring structure design avoids both the surface protrusions associated with traditional mechanical scoring and the thermal damage associated with laser scoring, achieving dual optimization of surface quality and magnetic performance. This unique scoring morphology opens up new technical possibilities for high-end applications of amorphous alloy ribbon 2.

[0085] In some embodiments, the V-shaped notch 21 includes two intersecting straight line notch segments 211 , and the two straight line notch segments 211 are symmetrically arranged along the length direction of the amorphous alloy strip 2 .

[0086] In the present invention, by configuring the V-shaped notch to include two intersecting linear notch segments 211, and symmetrically arranging these segments 211 along the length of the amorphous alloy ribbon 2, the uniformity of magnetic properties and the symmetry of stress distribution are optimized. This symmetrical notch structure ensures a uniform distribution of the magnetic domain blocking effect across the ribbon's width, avoiding the localized magnetic property differences and stress concentration that can result from asymmetric notches, thereby improving the ribbon's performance stability in applications such as transformer cores.

[0087] Specifically, the V-shaped structure formed by the two intersecting straight line scoring segments 211 creates a symmetrical magnetic blocking interface on the surface of the thin ribbon. The symmetrical arrangement along the length of the thin ribbon ensures the perfect geometric symmetry of the scoring. This symmetry is of great significance for the refinement of the magnetic domains, because the distribution and movement of magnetic domains in the material generally follow the principle of symmetry. The symmetrical scoring structure can better adapt to and guide the rearrangement of the magnetic domains. The inflection point formed by the intersection of the two straight line scoring segments 211 plays a role in strengthening magnetic blocking in magnetism, and the symmetrical arrangement makes this strengthening effect evenly distributed on both sides of the thin ribbon, avoiding the problem of excessive magnetic blocking on one side and insufficient on the other side.

[0088] In some embodiments, the angle between the two straight score segments 211 is between 90° and 180°.

[0089] In the present invention, by limiting the angle between the two linear score segments 211 to a range of 90°-180°, the V-shaped score's magnetic blocking function is optimized and the score structure's stability is guaranteed. The lower limit of 90° ensures sufficient angular variation to achieve effective multi-directional magnetic blocking, while the upper limit of 180° avoids weakening the magnetic blocking effect due to excessive score angles. This angle range ensures both magnetic performance and geometric stability of the score structure.

[0090] Specifically, the angle of the straight notch segment 211 directly affects the magnetic blocking efficiency and mechanical stability of the V-shaped notch. When the angle is 90°, the two notch segments are perpendicular to each other, forming the strongest directional magnetic blocking effect, which can effectively block the propagation paths of magnetic domains in different directions. As the angle increases, the directionality of the magnetic blocking gradually weakens, but it can still maintain an effective blocking function. When the angle approaches 180°, the two notch segments tend to be parallel. Although the magnetic blocking effect is weakened, it still has a better effect than a single straight notch. In the entire range of 90°-180°, the V-shaped notch can maintain good geometric stability and will not experience structural instability due to stress concentration caused by an angle that is too small.

[0091] like Figure 8 As shown, in some embodiments, the two straight score segments 211 form a second inflection point 212 at the intersection, and the distance c between the second inflection point 212 and the center line of the amorphous alloy strip 2 in the width direction satisfies: c≤d*20%, where d is the width of the amorphous alloy strip 2.

[0092] In the present invention, by limiting the distance c between the second inflection point 212 formed at the intersection of two linear score segments 211 and the widthwise centerline of the amorphous alloy ribbon 2 to c ≤ d*20% (where d is the width of the amorphous alloy ribbon 2), a centralized distribution of V-shaped score positions and optimized magnetic properties are achieved. This centralized score distribution ensures uniform magnetic properties across the ribbon's width, preventing edge effects from affecting overall performance, and promoting consistent and stable performance in ribbon lamination applications.

[0093] Specifically, the position of the second inflection point 212 directly affects the distribution pattern of the V-shaped notch on the ribbon and the spatial distribution of the magnetic blocking effect. When the distance between the second inflection point 212 and the center line of the ribbon in the width direction is controlled within 20% of the ribbon width, it ensures that the V-shaped notch is mainly distributed in the central area of ​​the ribbon. This area undertakes the main task of magnetic flux conduction in practical applications and has the highest requirements for magnetic property uniformity. The centralized distribution pattern makes the magnetic blocking effect symmetrically distributed relative to the center line of the ribbon, avoiding local magnetic property differences that may be caused by asymmetric distribution. At the same time, this position setting is also conducive to reducing the impact of edge effects, because the edges of the ribbon usually have microscopic defects formed during processing or treatment. If the notch is too close to the edge, it may aggravate the impact of these defects.

[0094] In a specific embodiment, for an amorphous alloy ribbon 2 with a width of 142 mm, the second inflection point 212 was set at 20 mm from the centerline (an offset of approximately 14%). Test results showed that the permeability variation within the effective width range of the ribbon was controlled within ±2%. However, when the second inflection point 212 was set at 40 mm from the centerline (an offset of approximately 28%), the permeability variation increased to ±6%. This demonstrates that centralizing the inflection point plays an important role in ensuring uniform magnetic properties.

[0095] like Figure 9 and 10 As shown, in some embodiments, the height of the protrusions on both sides of the V-shaped notch is less than 0.5 μm.

[0096] In this invention, by controlling the height of the protrusions on both sides of the V-shaped notch to less than 0.5 μm, the surface quality of the thin strip is significantly improved and the lamination performance is optimized. The low protrusion height reduces the air gap during the lamination of the thin strips, improving the lamination factor and the continuity of the magnetic circuit. The smooth surface quality also facilitates the subsequent processing and application of the thin strips, enhancing the market competitiveness and application range of the product.

[0097] Specifically, the height of the protrusions on both sides of the notch is an important indicator for evaluating the notch quality, which directly affects the lamination performance and actual application effect of the thin strip. Figure 11 、 12 As shown, traditional mechanical scoring uses cold processing, which easily forms obvious material accumulation on both sides of the scoring, forming a higher protrusion structure. However, the present invention uses heated scoring technology to allow the material to flow in a plastic state, avoiding brittle fracture and material accumulation, and greatly reducing the protrusion height on both sides of the scoring. A protrusion height of less than 0.5μm means a significant improvement in surface roughness. When multiple layers of thin strips are laminated, the tiny protrusions will not form obvious air gaps, ensuring the tightness of the lamination and the continuity of the magnetic circuit. This improvement in surface quality is of great significance for improving the lamination factor and reducing iron loss.

[0098] In a specific embodiment, the scored ribbon produced using the present invention has a surface protrusion height of 0.3 μm. When used in transformer core manufacturing, the lamination factor reaches 0.92, a significant improvement over the 0.85 of conventional scored ribbon. Furthermore, due to its smooth surface, the ribbon is less susceptible to scratches or damage during handling and processing, improving product quality and service life.

[0099] Preferably, the amorphous alloy strip 2 manufactured by the technology of the present invention has no protrusions on both sides of the V-shaped notch.

[0100] In some embodiments, the V-shaped notches 21 are spaced apart along the length direction of the amorphous alloy strip 2 , and the number of intersections between any straight line along the width direction of the amorphous alloy strip 2 and the V-shaped notches 21 is 2-6.

[0101] In the present invention, by controlling the spacing of V-shaped notches along the length of the amorphous alloy ribbon 2 and limiting the number of intersections between any straight line along the width of the ribbon and the V-shaped notches to 2-6, precise control of notch density and optimization of processing stability are achieved. The present invention does not limit the specific width between adjacent notches, but ensures that a straight line drawn along the width of the ribbon at any position on the ribbon intersects with the row of notches on the surface of the amorphous ribbon at between 2-6 points. This limitation effectively controls the unit pressure at the contact point between the blade and the ribbon, while maintaining constant pressure during the notching process, and avoids technical problems caused by too dense notches or too small an angle.

[0102] Specifically, the control of the number of intersections has profound technical connotations and practical significance. During the scoring process, since the pressure is constant, the number of contact points between the blade and the strip directly affects the pressure distribution of a single contact point. When the number of intersections is too large, it means that the scoring spacing is too dense or the inflection point angle is too small, which will bring about many technical problems. The excessively dense scoring spacing first brings difficulties to the production of the knife roller 1. It is necessary to set too many blades on a limited circumferential surface, which not only increases the manufacturing difficulty and cost, but also may affect the mechanical strength and dynamic balance performance of the knife roller 1. More importantly, when the inflection point angle is too small, the scoring on both sides of the inflection point forms a smaller angle with the length direction of the strip (that is, the direction of travel when the scoring is working), resulting in the forward force being decomposed more into lateral force, destroying the strip positioning function of the V-shaped blade, causing the strip to be laterally offset during the production process, affecting product quality and production stability.

[0103] In some embodiments, the straight line scoring segments 211 are in the form of dots, lines, or a combination of dots and lines.

[0104] In this invention, by designing linear score segments 211 in various forms, such as dot, line, or a combination of dot and line, the score structure is diversified and the magnetic blocking function is optimized. Dot score segments provide a localized, concentrated magnetic blocking effect, while line score segments provide a continuous magnetic blocking path. The combination of dot and line combines the advantages of both. The most suitable score form can be selected based on different magnetic performance requirements and application scenarios, expanding the scope of application and application flexibility of the technical solution.

[0105] Specifically, different forms of linear scoring segments 211 have their own unique magnetic properties and application advantages. Point-shaped scoring segments form localized magnetic blocking points in the material through discrete point structures. These blocking points act as "roadblocks" on the magnetic domain propagation path, effectively interfering with the continuous propagation of the magnetic domains and are suitable for applications requiring precise control of the magnetic blocking position. Linear scoring segments form continuous magnetic blocking lines that can uniformly block the propagation of magnetic domains over a large area, making them suitable for applications requiring a large-area magnetic blocking effect. Point-line combined scoring segments combine the advantages of both point and line structures, possessing both the local strengthening effect of a point-shaped structure and the continuous blocking function of a line-shaped structure, enabling more complex and precise magnetic domain control.

[0106] Table 1 lists the parameters of the mechanically scored amorphous alloy ribbon and the laser-scored amorphous alloy ribbon prepared according to the method of the present invention.

[0107] Table 1 shows a comparison of some parameters of a mechanically scored tape obtained by the mechanical scoring method of the present invention and a conventional scored tape using the same FeSiBC-based amorphous alloy strip as a substrate. The embodiment is a V-shaped scoring with a second inflection angle of 160°. The specifications of the scored ribbons in both the examples and comparative examples are: a score spacing of 15 mm; a score depth ranging from 0.5 to 4.5 μm, preferably 1.5 μm; and a score width ranging from 30 to 80 μm, preferably 50 μm. Examples 1-7 are amorphous alloy ribbons produced using this method, using blade heating. Comparative Examples 1 and 2 use either a horizontal linear roller or a spiral roller with unheated blades. Comparative Example 3 uses an unscored raw ribbon. Comparative Example 4 uses a laser-scored ribbon.

[0108] Table 1

[0109] It can be seen from the comparative analysis of the above embodiments and comparative examples that: 1. Significant Advantages of the Present Invention: Examples 1-7, using a V-shaped blade mechanical scoring method, achieved iron loss reductions of 48.8%-51.8%, significantly outperforming the traditional scoring methods (48.9%-49.4%) used in Comparative Examples 1, 2, and 4. Quantified technical results show a 15-25% reduction in iron loss compared to unscored ribbons of the same material, clearly demonstrating the significant superiority and practical application value of the technical solution.

[0110] 2. The superiority of the V-shaped structure: Compared to straight-line notches (Comparative Examples 1, 2, and 4), V-shaped notches provide better magnetic domain refinement, reducing iron loss by 1-3 percentage points. By forming a V-shaped notch structure with a stepped cross-sectional morphology, a unique multi-level magnetic domain refinement mechanism and excellent surface quality control are achieved.

[0111] 3. Mechanical scoring 21 vs. laser scoring: The mechanical V-shaped scoring method of the present invention avoids the thermal damage problem of laser scoring, while achieving similar iron loss improvement effects and maintaining a better lamination factor.

[0112] 4. Parameter Optimization Effect: Example 5 achieved the best iron loss reduction (51.8%) at a 90° V-shaped angle, demonstrating the rationality of the angle range setting. By optimizing the angle between the straight notches on either side of the V-shaped notch's inflection point to within a range of 135°-165°, the magnetic domain refinement effect was maximized.

[0113] 5. Process stability: The iron loss values ​​of the various examples were within the range of 0.0542-0.0575 W / kg, with a small variation, indicating that the process of the present invention has good stability and reproducibility.

[0114] 6. Surface quality advantage: The protrusion height of each embodiment of the present invention is less than 0.5 μm, which is significantly better than the 1.2-1.5 μm of the comparative example, ensuring good lamination performance.

[0115] 7. Intelligent control technology: By monitoring strip deviation during the heating process and automatically correcting it, stable control of product quality and significant improvement in production efficiency are achieved during continuous production.

[0116] 8. Precise temperature control: By adopting a combined heating device of internal thermocouple and external infrared auxiliary heating equipment, the precise measurement and rapid adjustment of the blade temperature are achieved, ensuring the accuracy and stability of temperature control during the notching process.

[0117] In summary, the low-loss amorphous alloy strip manufacturing method and product provided by the present invention have significant advantages in iron loss reduction effect, surface quality, process stability, etc., and provide an effective technical solution for the high-performance application of amorphous alloy materials.

[0118] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units, i.e., they may be located in one location or distributed across multiple network units. Some or all of the modules may be selected based on actual needs to achieve the objectives of the present embodiment. Persons of ordinary skill in the art will be able to understand and implement the present invention without inventive effort.

[0119] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A method for manufacturing a V-shaped notched amorphous alloy ribbon, characterized in that: include: Using a knife roller (1) to form a notch on a smooth amorphous alloy strip; The knife roller (1) has a cylindrical main body (11), and a V-shaped blade portion (12) is protrudingly provided on the outer peripheral surface of the cylindrical main body (11); During the scoring operation, the knife roller (1) presses against the amorphous alloy strip and rotates along the travel direction of the amorphous alloy strip, thereby obtaining an amorphous alloy thin strip (2) with V-shaped scoring (21) on the surface.

2. The method according to claim 1, characterized in that The V-shaped blade portion (12) comprises two intersecting straight blade segments (121), and the two straight blade segments (121) are symmetrically arranged with respect to a radial section passing through the intersection thereof.

3. The method according to claim 1, characterized in that The blade angle of the V-shaped blade portion (12) is within the range of 15°-45°.

4. The method according to claim 2, characterized in that The two straight blade segments (121) form a first inflection point (122) at the intersection, and the distance a between the first inflection point (122) and the midpoint of the length direction of the knife roller (1) satisfies: a≤b*40%, wherein b is the length of the knife roller (1).

5. The method according to any one of claims 1 to 4, characterized in that The knife roller (1) is provided with a heating device, and the heating temperature of the V-shaped blade (12) is greater than the ductile-brittle transition temperature of the amorphous alloy strip and less than the crystallization temperature of the amorphous alloy strip.

6. The method according to claim 1, characterized in that During the scoring operation, the pressure between the V-shaped blade (12) and the amorphous alloy strip is in the range of 0.1-1 MPa / cm².

7. An amorphous alloy ribbon, characterized in that: The surface of the amorphous alloy thin strip (2) has a V-shaped notch (21).

8. The amorphous alloy ribbon according to claim 7, characterized in that: The cross section of the V-shaped notch (21) is a stepped structure with its width increasing towards the opening direction.

9. The amorphous alloy ribbon according to claim 7, characterized in that: The V-shaped notch (21) comprises two intersecting straight line notch segments (211), and the two straight line notch segments (211) are symmetrically arranged along the length direction of the amorphous alloy thin strip (2).

10. The amorphous alloy ribbon according to claim 9, characterized in that: The two straight line notch segments (211) form a second inflection point (212) at their intersection, and a distance c between the second inflection point (212) and the center line of the amorphous alloy strip (2) in the width direction satisfies: c≤d*20%, wherein d is the width of the amorphous alloy strip (2).

11. The amorphous alloy ribbon according to claim 7, characterized in that: The V-shaped notches (21) are arranged at intervals along the length direction of the amorphous alloy thin strip (2), and the number of intersections between any straight line along the width direction of the amorphous alloy thin strip (2) and the V-shaped notches (21) is 2-6.

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