Soft magnetic material composite strip and manufacturing method thereof

Abstract

The invention discloses a soft magnetic material composite strip and a manufacturing method, the soft magnetic material composite strip is composed of at least two layers of alloy strips which are laminated and overlapped together after being bonded by a pressure-sensitive adhesive, and any layer of alloy strip is made of one of amorphous alloy, oriented silicon steel and non-oriented silicon steel; the thickness of the composite strip ranges from 0.05 mm to 0.5 mm. The soft magnetic material composite strip disclosed by the invention can be produced on a large scale in a stamping forming mode, is used for producing stator and rotor iron cores of transformers and motors, and has the advantages of high production efficiency and high yield.

Description

Technical Field

[0001] This invention belongs to the field of soft magnetic materials used in the manufacture of motor and transformer cores, and specifically relates to a soft magnetic material composite strip and its manufacturing method. Background Technology

[0002] With the miniaturization and high-frequency operation of motors and transformers, the soft magnetic alloy materials used are evolving from ultra-thin (0.1-0.15mm) to extremely thin (0.02-0.1mm). Mass production of iron core products typically employs stamping, but the minimum thickness for stamping is generally 0.1mm. For soft magnetic alloy materials thinner than 0.1mm, stamping is not feasible. For example, stamping cannot process amorphous alloys with a single-layer thickness of 0.025mm or silicon steel with a single-layer thickness of 0.05-0.08mm.

[0003] In the past two years, domestic companies have begun to develop amorphous composite tape preparation technology. Currently, the adhesives used by these companies to prepare composite tapes are limited to two main categories: anaerobic adhesives and water-based epoxy adhesives. Anaerobic adhesives are expensive, and water-based epoxy adhesives have long curing times, making both unsuitable for large-scale production of amorphous composite tapes. Summary of the Invention

[0004] This invention discloses a soft magnetic material composite strip, the purpose of which is to solve the problem that existing soft magnetic material composite strips are not suitable for stamping and therefore cannot be used on a large scale in the manufacture of iron cores. The specific technical solution is as follows: A soft magnetic material composite strip, wherein the soft magnetic material composite strip is composed of at least two alloy strips bonded together with pressure-sensitive adhesive and then pressed and overlapped, wherein any one of the alloy strips is made of one of amorphous alloy, oriented silicon steel and non-oriented silicon steel; the thickness of the composite strip ranges from 0.05mm to 0.5mm; Furthermore, the soft magnetic material composite strip is a two-layer alloy strip, each layer being made of non-oriented silicon steel; Furthermore, the soft magnetic material composite strip comprises at least three alloy strips, wherein the uppermost alloy strip and the bottommost alloy strip are both non-oriented silicon steel, and the middle layer is one of the amorphous alloy, oriented silicon steel and non-oriented silicon steel. Furthermore, the width of each alloy strip layer is equal.

[0005] Furthermore, in the soft magnetic material composite strip as described in claim 1, the pressure-sensitive adhesive is one or a combination of several of the following: rubber-type pressure-sensitive adhesive, acrylic-type pressure-sensitive adhesive, silicone-type pressure-sensitive adhesive, and thermoplastic elastomer pressure-sensitive adhesive; the coating thickness of the pressure-sensitive adhesive in each alloy strip layer ranges from 0.1 micrometers to 10 micrometers.

[0006] Furthermore, the surface of any layer of the alloy strip is either an exposed substrate or coated with other insulating coatings.

[0007] The soft magnetic material composite strip disclosed in this invention has the following technical effects: (1) Since the soft magnetic material composite strip contains at least two alloy strips, and each pair of alloy strips is bonded with pressure-sensitive adhesive instead of conventional anaerobic adhesive or water-based epoxy adhesive, and the material of any one of the alloy strips is one of amorphous alloy, oriented silicon steel and non-oriented silicon steel, the thickness range of the soft magnetic material composite strip is controlled between 0.05mm and 0.5mm. Therefore, the soft magnetic material composite strip can be used for mass production of stamping. The soft magnetic material composite strip is used to manufacture transformer and motor stator and rotor cores, which has the advantage of high production efficiency.

[0008] (2) If the top layer and bottom layer of the soft magnetic composite strip are both non-oriented silicon steel, and at least one layer in the middle can be amorphous alloy, oriented silicon steel and non-oriented silicon steel, and each pair of adjacent alloy strips are bonded with pressure-sensitive adhesive, since non-oriented silicon steel is more suitable for stamping than amorphous alloy and oriented silicon steel, thus improving the yield, it is more suitable for large-scale manufacturing for transformer and motor stator and rotor cores, thereby increasing production capacity.

[0009] This application also discloses a method for manufacturing the aforementioned soft magnetic material composite strip, comprising the following steps: A coating device with the same number of layers as the alloy strips constituting the soft magnetic material composite tape is used to coat the corresponding side of each alloy strip involved in the contact surface of each two adjacent layers with pressure-sensitive adhesive. After each alloy strip is dried by a drying device, it is pressed into the soft magnetic material composite tape by a pressing device at room temperature and then wound up by a winding machine.

[0010] Furthermore, the coating thickness of the pressure-sensitive adhesive is 0.1 micrometers to 10 micrometers.

[0011] Furthermore, the coated alloy strips are passed through the drying device, first undergoing solvent removal at (50-250)℃ / 2min, and then curing at (50-250)℃ / 6min.

[0012] Furthermore, the drying device is a tunnel oven; the pressing method is one or a combination of roller pressing, flat pressing, molding pressing and scraper pressing.

[0013] Technical effects: (1) The soft magnetic composite strip manufactured by this method reduces the stamping difficulty and is suitable for large-scale production by stamping. The stamping forming method is used for large-scale production of transformer and motor stator and rotor cores, which has the advantages of high production efficiency and high yield. (2) Each alloy strip of the soft magnetic composite strip is desolventized at (50-250)℃ / 2min, cured at (50-250)℃ / 6min, and then pressed by the pressing equipment at room temperature. This avoids the problem of thermal stress generated at room temperature after high-temperature composite, which leads to the deterioration of the magnetic properties of the soft magnetic material. Attached Figure Description

[0014] Figure 1 A schematic diagram of a soft magnetic material composite strip consisting of two alloy strips, each of which is a non-oriented silicon steel strip 11; Figure 2 A schematic diagram of a soft magnetic material composite strip with three alloy strips, wherein the top and bottom layers are non-oriented silicon steel strips 11, and the middle layer is an amorphous alloy strip 13; Figure 3 The soft magnetic material composite strip has six alloy strips, of which the top and bottom layers are non-oriented silicon steel strips 11, and the middle four layers are, from top to bottom, amorphous alloy strips 13, oriented silicon steel strips 14, amorphous alloy strips 13 and oriented silicon steel strips 14. Figure 4 This is a schematic diagram of the manufacturing process of soft magnetic material composite strips. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, unless otherwise explicitly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0017] refer to Figures 1 to 3 The soft magnetic composite tape described in this application includes: an alloy tape consisting of at least two layers bonded together with pressure-sensitive adhesive and then pressed and overlapped, wherein any one layer of the alloy tape is made of an amorphous alloy, oriented silicon steel, or non-oriented silicon steel; the thickness of the composite tape is in the range of 0.05mm-0.5mm.

[0018] For example: Figure 1 In this process, the soft magnetic material composite tape consists of two alloy tapes, each being a non-oriented silicon steel tape 11. The contact surfaces of the two non-oriented silicon steel tapes 11—namely, the lower surface of the upper non-oriented silicon steel tape 11 and the upper surface of the lower non-oriented silicon steel tape 11—are coated with pressure-sensitive adhesive 12. After both non-oriented silicon steel tapes 11 are coated with pressure-sensitive adhesive 12 and dried, they are then fed into a pressing device for pressing to obtain the soft magnetic material composite tape. It should be noted that... Figure 1 The two alloy strips in the text, both being non-oriented silicon steel strips 11, are merely exemplary. Because non-oriented silicon steel strips 11 have good stamping properties, the soft magnetic composite strip formed by bonding two layers of non-oriented silicon steel strips 11 together after coating with pressure-sensitive adhesive is suitable for stamping. This facilitates large-scale production of transformer and motor stator / rotor cores using stamping forming methods, offering the advantage of high production efficiency. Of course, in... Figure 1When a soft magnetic composite tape has only two layers, the materials of the two layers can be different. For example, the top layer can be made of one of the following materials: amorphous alloy, oriented silicon steel, or non-oriented silicon steel. The bottom layer can also be made of one of these materials, with pressure-sensitive adhesive 12 still coated in between. However, the stamping performance of this type of soft magnetic composite tape will be somewhat worse because the stamping performance of amorphous alloys and oriented silicon steel is generally worse than that of non-oriented silicon steel. (Reference) Figure 2 If the soft magnetic material composite tape has three alloy layers, each of these three layers can be one of amorphous alloy, oriented silicon steel, or non-oriented silicon steel. In other words, they can be the same or different from each other. Figure 2 This illustration is merely to show a scenario where the top and bottom layers are both non-oriented silicon steel strips 11, and the middle layer is an amorphous alloy strip 13. It should be noted that, in terms of stamping performance, non-oriented silicon steel > oriented silicon steel > amorphous alloy. Therefore, if all three layers are non-oriented silicon steel strips 11, the soft magnetic material composite strip has the best stamping performance; if all three layers are amorphous alloys, the soft magnetic material composite strip has the worst stamping performance. It should also be noted that when the soft magnetic material composite strip, exemplarily, includes three alloy strips, pressure-sensitive adhesive 12 is also required between each adjacent pair of layers. (Reference) Figure 3 , Figure 3 The soft magnetic material composite tape consists of six alloy strips. The top and bottom layers are both non-oriented silicon steel strips 11. The middle four layers, from top to bottom, are amorphous alloy strip 13, oriented silicon steel strip 14, amorphous alloy strip 13, and oriented silicon steel strip 14, respectively. Each adjacent alloy strip layer is coated with pressure-sensitive adhesive 12, dried, and then pressed together. Similarly, each of these six alloy strip layers can be one of amorphous alloy, oriented silicon steel, or non-oriented silicon steel. It is understood that if all six layers are non-oriented silicon steel strips 11, the soft magnetic material composite tape has the best stamping performance; if all six layers are amorphous alloys, the soft magnetic material composite tape has the worst stamping performance.

[0019] In the aforementioned soft magnetic material composite strip, the width of each alloy strip layer is equal, while the total thickness of the soft magnetic material composite strip varies depending on the number of alloy strip layers, generally remaining between 0.05mm and 0.5mm. This total thickness range is suitable for stamping equipment to stamp it, facilitating large-scale mass production and improving the yield.

[0020] In this application, the pressure-sensitive adhesive is one or a combination of several of the following: rubber-based pressure-sensitive adhesive, acrylic-based pressure-sensitive adhesive, silicone-based pressure-sensitive adhesive, and block copolymer pressure-sensitive adhesive; it can also be one or a combination of several of the following: hot-melt pressure-sensitive adhesive, water-based pressure-sensitive adhesive, hot-melt pressure-sensitive adhesive, and ultraviolet (UV) curable pressure-sensitive adhesive. Since anaerobic adhesives are expensive and water-based epoxy adhesives have long curing times, neither of these adhesives can be used for the large-scale production of amorphous composite tapes. Therefore, pressure-sensitive adhesives are chosen because they are inexpensive and suitable for mass production. It should be noted that, preferably, when using pressure-sensitive adhesives to coat the corresponding surfaces of the alloy tapes (i.e., the contact surfaces between every two adjacent layers of alloy tape constituting the soft magnetic material composite tape), the coating thickness ranges from 0.1 micrometers to 10 micrometers.

[0021] In some embodiments, the surface of any layer of the alloy strip is either an exposed substrate or coated with an insulating coating. An exposed substrate serves to ensure basic magnetic energy, improve core parameters, and simplify production costs. An insulating coating, on the other hand, can suppress eddy current losses, improve interlayer withstand voltage, prevent breakdown damage, and enhance the strip's protective properties.

[0022] The soft magnetic material composite tape disclosed in this application has the following technical advantages: (1) Since the soft magnetic material composite strip contains at least two alloy strips, and each two alloy strips are bonded with pressure-sensitive adhesive instead of conventional anaerobic adhesive or water-based epoxy adhesive, and the material of any one of the alloy strips is one of amorphous alloy, oriented silicon steel and non-oriented silicon steel, and the thickness of the soft magnetic material composite strip is controlled between 0.05mm and 0.5mm, the soft magnetic material composite strip can be mass-produced by stamping and used for transformer and motor stator and rotor cores, which has the advantage of high production efficiency.

[0023] (2) If the top layer and bottom layer of the soft magnetic composite strip are both non-oriented silicon steel, and at least one layer in the middle can be amorphous alloy, oriented silicon steel and non-oriented silicon steel, and each pair of adjacent alloy strips are bonded with pressure-sensitive adhesive, since non-oriented silicon steel is more suitable for stamping than amorphous alloy and oriented silicon steel, thus improving the yield, it is also more suitable for use in specific industry fields of large-scale manufacturing of transformer and motor stator and rotor cores.

[0024] This application also discloses a method for manufacturing the aforementioned soft magnetic material composite strip, comprising the following steps: Using the same number of coating devices as the alloy strips constituting the soft magnetic material composite tape, pressure-sensitive adhesive is applied to the corresponding side of each alloy strip involved in the contact surface of each two adjacent layers. After drying, the strips are pressed together at room temperature by a pressing device and then wound up by a winding machine.

[0025] In some embodiments, the coating thickness of the pressure-sensitive adhesive is 0.1 micrometer to 10 micrometers.

[0026] In some embodiments, the coated alloy strips are passed through the drying device, first undergoing solvent removal at (50-250)℃ / 2min, and then curing at (50-250)℃ / 6min.

[0027] In some embodiments, the drying apparatus is a tunnel oven; the pressing method is one or a combination of roller pressing, flat pressing, molding pressing and scraper pressing.

[0028] The following is combined with Figure 4 The method for manufacturing soft magnetic material composite tape described above will be described in detail. Figure 4 In this process, there are n layers of alloy strips. Each corresponding surface of an alloy strip is coated with pressure-sensitive adhesive by n coating devices, then sent to a drying device for drying. After drying, it is pressed at room temperature by a pressing device, finally obtaining a soft magnetic material composite strip containing n alloy strips. It should be noted that the value of n here must satisfy the requirement that the thickness of the soft magnetic material composite strip is between 0.05mm and 0.5mm. The corresponding surface of each alloy strip refers to the contact surface between every two adjacent alloy strips. For example, refer to... Figure 2 The lower surface of the topmost non-oriented silicon steel strip 11 is coated with pressure-sensitive adhesive using the first coating device (coating 1). The upper and lower surfaces of the middle oriented silicon steel strip 14 are coated with pressure-sensitive adhesive using the second coating device (coating 2). It can be understood that the upper surface of the bottommost non-oriented silicon steel strip 11 is coated with pressure-sensitive adhesive using the last coating device. The coating thickness of the pressure-sensitive adhesive for each alloy strip ranges from 0.1 micrometers to 10 micrometers. After the soft magnetic composite strip is coated, it is first dried at (50-250)℃ for 2 minutes to remove solvent, then cured at (50-250)℃ for 6 minutes, and finally pressed at room temperature using a pressing device, and finally wound up using a winding machine. In this application, the pressing method is one or a combination of roll pressing, flat pressing, die pressing, and scraper pressing; other pressing methods can also be used. The soft magnetic composite strip produced by this method is suitable for large-scale production of transformer and motor stator and rotor cores by stamping, and has the advantage of high production efficiency.

[0029] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A soft magnetic material composite strip, characterized in that, The soft magnetic material composite strip is composed of at least two alloy strips bonded together with pressure-sensitive adhesive and then pressed and overlapped, wherein any one of the alloy strips is made of an amorphous alloy, oriented silicon steel, or non-oriented silicon steel; the thickness of the composite strip ranges from 0.05mm to 0.5mm.

2. The soft magnetic material composite strip as described in claim 1, characterized in that, The soft magnetic material composite strip is a two-layer alloy strip, with each layer made of non-oriented silicon steel.

3. The soft magnetic material composite strip as described in claim 1, characterized in that, The soft magnetic material composite strip comprises at least three alloy strips, wherein the topmost and bottommost alloy strips are both non-oriented silicon steel, and the middle at least one is one of amorphous alloy, oriented silicon steel, and non-oriented silicon steel.

4. The soft magnetic material composite strip as described in claim 1, characterized in that, The width of each layer of the alloy strip is equal.

5. The soft magnetic material composite strip as described in claim 1, characterized in that, The pressure-sensitive adhesive is one or a combination of several of the following: rubber-type pressure-sensitive adhesive, acrylic-type pressure-sensitive adhesive, silicone-type pressure-sensitive adhesive, and thermoplastic elastomer pressure-sensitive adhesive; the coating thickness of the pressure-sensitive adhesive on each alloy strip ranges from 0.1 micrometers to 10 micrometers.

6. The soft magnetic material composite strip as described in claim 1, characterized in that, The surface of any layer of the alloy strip is either an exposed substrate or coated with an insulating coating.

7. A method for manufacturing a soft magnetic material composite tape as described in any one of claims 1 to 6, characterized in that, Includes the following steps: A coating device with the same number of layers as the alloy strips constituting the soft magnetic material composite tape is used to coat the corresponding side of each alloy strip involved in the contact surface of each two adjacent layers with pressure-sensitive adhesive. After each alloy strip is dried by a drying device, it is pressed into the soft magnetic material composite tape by a pressing device at room temperature and then wound up by a winding machine.

8. The method as described in claim 7, characterized in that, The coating thickness of the pressure-sensitive adhesive on the corresponding side of the alloy strip is 0.1 micrometer to 10 micrometers.

9. The method as described in claim 7, characterized in that, The drying process of the drying device is as follows: the coated alloy strips are passed through the drying device, first at (50-250)℃ / 2min to remove solvent, and then at (50-250)℃ / 6min to cure.

10. The method as described in claim 7, characterized in that, The drying device is a tunnel furnace; the pressing method is one or a combination of roller pressing, flat pressing, molding pressing and scraper pressing.

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