A preparation method of a new energy core based on amorphous alloy material

Abstract

The application provides a preparation method of a new energy core based on amorphous alloy material, and comprises the following steps: alternately winding amorphous alloy strip and flexible polymer film by using a set gradient tension curve, synchronously performing laser positioning, realizing interlayer alignment control, and forming an internal stress buffer layer; winding the amorphous alloy strip on the internal stress buffer layer by using a set gradient tension curve, and forming a main magnetic circuit functional layer; manufacturing an outer protective layer on the outer surface of the main magnetic circuit functional layer to obtain a formed core; and annealing the formed core to obtain a new energy core; the application cooperatively realizes internal stress buffering, uniform distribution of interlayer stress and improvement of magnetic circuit continuity, thereby effectively inhibiting mechanical stress and micro-damage in the winding process, and significantly improving the magnetic property stability and energy efficiency level of the core under high-frequency working conditions.

Description

Technical Field

[0001] This invention belongs to the field of soft magnetic material manufacturing technology, specifically relating to a method for preparing a new energy iron core based on amorphous alloy materials. Background Technology

[0002] Amorphous alloys are widely used in high-efficiency and energy-saving power equipment due to their excellent soft magnetic properties, such as high permeability, low iron loss, and high saturation magnetic induction. However, amorphous alloy strips are extremely thin (typically 20–30 μm), hard, and brittle, making them prone to microcracks, residual stress, and interlayer dislocations during traditional core winding processes. This leads to significant deterioration of magnetic properties, especially a sharp increase in eddy current losses under high-frequency (>1 kHz) operating conditions. Furthermore, existing winding processes often employ constant tension control, which is ill-suited to the uneven stress distribution caused by curvature changes during winding of amorphous strips. This results in compression of the inner ring and stretching of the outer ring, further worsening the uniformity of magnetic properties. In new energy applications, the requirements for high-frequency, low-loss, high-stability, and miniaturized cores are even more stringent, necessitating the development of a novel winding process to improve the overall performance and reliability of amorphous alloy cores. Summary of the Invention

[0003] The purpose of this invention is to provide a method for preparing a new energy core based on amorphous alloy materials. By optimizing the winding tension control strategy, introducing a stress buffer layer and a precise positioning structure, the mechanical stress and micro-damage during the winding process are effectively suppressed, and the magnetic performance stability and energy efficiency of the core under high-frequency operating conditions are significantly improved.

[0004] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, the present invention provides a method for preparing a new energy core based on an amorphous alloy material, comprising the following steps: A pre-defined gradient tension curve is used to alternately wind amorphous alloy strip and a flexible polymer film, while simultaneously performing laser positioning to achieve interlayer alignment control and form an internal stress buffer layer. An amorphous alloy strip is wound onto an internal stress buffer layer using a set gradient tension curve to form the main magnetic circuit functional layer. An outer protective layer is fabricated on the outer surface of the main magnetic circuit functional layer to obtain the formed iron core. The formed iron core is annealed to obtain a new energy iron core.

[0005] Preferably, the amorphous alloy strip and the flexible polymer film are alternately wound using a predetermined gradient tension curve. Specifically, the method is as follows: The tension applied to the amorphous alloy strip decreases monotonically from the starting radius to the target radius.

[0006] Preferably, the tension value satisfies the following formula:

[0007] in, Let r be the winding tension at a radius r from the center of the iron core; The initial tension; The inner diameter of the iron core; This is the attenuation coefficient.

[0008] Preferably, the flexible polymer film is a polyimide, polyetheretherketone, or a liquid crystal polymer.

[0009] Preferably, the thickness of the flexible polymer film is 10 μm–25 μm.

[0010] Preferably, the process parameters for annealing are: Annealing was carried out under an inert atmosphere at a temperature of 320℃–380℃ for 1–2 hours.

[0011] Preferably, the outer protective layer is formed by impregnation and curing with a high-temperature resistant insulating resin.

[0012] Secondly, the present invention provides a new energy iron core based on amorphous alloy material, wherein the new energy iron core is prepared based on the preparation method described above.

[0013] Preferably, the new energy core comprises, from the inside out, an internal stress buffer layer, a main magnetic circuit functional layer, and an outer protective layer, wherein: The internal stress buffer layer is composed of alternating layers of flexible polymer film and amorphous ribbon; The main magnetic circuit functional layer is composed of stacked amorphous ribbon.

[0014] Preferably, the outer protective layer is formed by impregnation and curing with a high-temperature resistant insulating resin.

[0015] Compared with the prior art, the beneficial effects of the present invention are: This invention provides a method for preparing a new energy core based on amorphous alloy materials. By alternately winding amorphous alloy strip and a flexible polymer film using a predetermined gradient tension curve, and simultaneously implementing laser positioning to control interlayer alignment, combined with the fabrication of an outer protective layer and subsequent annealing, the method synergistically achieves internal stress buffering, uniform interlayer stress distribution, and improved magnetic circuit continuity. This effectively suppresses mechanical stress and microscopic damage during the winding process, significantly improving the magnetic performance stability and energy efficiency of the core under high-frequency operating conditions. It is particularly suitable for new energy equipment fields with stringent requirements for high-frequency, low-loss, and high-power-density operation. Specifically: The flexible polymer film effectively relieves the compressive stress in the inner ring and avoids brittle fracture of the amorphous ribbon. Gradient variable tension winding makes the stress distribution of each layer of the iron core uniform, which significantly reduces hysteresis loss and eddy current loss (measured at 10 kHz, iron loss is reduced by 18–25%). High-precision interlayer alignment improves magnetic circuit continuity and reduces local eddy current hotspots. Detailed Implementation

[0016] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0017] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0018] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0019] As used in this application specification and the appended claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrases "if determined" or "if detected [the described condition or event]" may be interpreted, depending on the context, as meaning "once determined," "in response to determination," "once detected [the described condition or event]," or "in response to detection [the described condition or event]."

[0020] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0021] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0022] Example 1 This embodiment provides a method for preparing a new energy core based on amorphous alloy materials, including the following steps: Step 1: Clean the surface of the amorphous alloy strip and create laser positioning marks in its width direction; Step 2: Pre-attach a flexible polymer film to the winding mandrel and start the winding machine; Step 3: The amorphous alloy strip is wound in multiple stages of variable tension according to the set gradient tension curve. At the same time, the vision alignment system is activated to capture the laser positioning mark for interlayer alignment control. After the winding is completed, an internal stress buffer layer is obtained. The internal stress buffer layer is composed of a flexible polymer film and the amorphous strip alternately stacked. Step 4: According to the set gradient tension curve, the amorphous alloy strip is wound on the internal stress buffer layer to form the main magnetic circuit functional layer. Step 5: Apply high-temperature resistant insulating resin to the main magnetic circuit functional layer to form an outer protective layer, and then cure it; Step 6: Place the formed integral iron core in an annealing furnace for stress relief heat treatment to obtain a new energy iron core.

[0023] Example 2 Based on Example 1, this example provides a method for preparing a new energy core based on amorphous alloy materials. The method involves multi-stage variable tension winding of the amorphous alloy strip according to a set gradient tension curve. Specifically: The amorphous alloy strip is continuously wound under tension to form a laminate, wherein the tension changes continuously during the winding process, and the tension applied to the amorphous alloy strip decreases as the winding radius increases.

[0024] Example 3 Based on Example 2, this example provides a method for preparing a new energy core based on amorphous alloy materials, wherein the tension value decreases monotonically from the starting radius of the winding to the target radius.

[0025] In this embodiment, the attenuation law of the tension value as the winding radius increases conforms to a preset exponential function relationship, which is as follows:

[0026] in, Let r be the winding tension at a radius r from the center of the iron core; As the initial tension, in this embodiment, 5–15 N; The inner diameter of the iron core, In this embodiment, the attenuation coefficient is... It is 0.02 mm. - ¹–0.08 mm - ¹.

[0027] Example 4 Based on Example 1, this example provides a method for preparing a new energy core based on amorphous alloy materials, wherein the flexible polymer film is polyimide (PI), polyether ether ketone (PEEK), or liquid crystal polymer (LCP).

[0028] The thickness of the flexible polymer film is 10 μm–25 μm.

[0029] Example 5 Based on Example 1, this example provides a method for preparing a new energy core based on amorphous alloy materials, wherein the annealing process parameters are as follows: Annealing was carried out under an inert atmosphere at a temperature of 320℃–380℃ for 1–2 hours.

[0030] Example 6 Based on Example 1, this example provides a method for preparing a new energy core based on amorphous alloy materials, with an interlayer alignment error ≤ ±0.1 mm.

[0031] Example 7 This embodiment provides a new energy iron core based on amorphous alloy material, comprising a toroidal iron core body, wherein an outer protective layer is provided on the outer surface of the toroidal iron core body, wherein: The annular core body includes an internal stress buffer layer and a main magnetic circuit functional layer from the inside out. The internal stress buffer layer is composed of a flexible polymer film and amorphous ribbon alternately wound, which can effectively disperse the inner ring compressive stress in the initial stage of winding, prevent the amorphous ribbon from brittle fracture, and improve interlayer insulation and mechanical toughness. The main magnetic circuit functional layer is composed of amorphous ribbon wound.

[0032] Example 8 Based on Example 7, this example provides a new energy iron core based on amorphous alloy material. The outer protective layer is made by impregnation and curing with high-temperature resistant insulating resin, which is used to fix the shape of the iron core and provide electrical insulation.

[0033] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A method for preparing a new energy core based on amorphous alloy materials, characterized in that, Includes the following steps: A pre-defined gradient tension curve is used to alternately wind amorphous alloy strip and a flexible polymer film, while simultaneously performing laser positioning to achieve interlayer alignment control and form an internal stress buffer layer. An amorphous alloy strip is wound onto an internal stress buffer layer using a set gradient tension curve to form the main magnetic circuit functional layer. An outer protective layer is fabricated on the outer surface of the main magnetic circuit functional layer to obtain the formed iron core. The formed iron core is annealed to obtain a new energy iron core.

2. The method for preparing a new energy core based on amorphous alloy material according to claim 1, characterized in that, The amorphous alloy strip and flexible polymer film are alternately wound using a predefined gradient tension curve. Specifically, the method is as follows: The tension applied to the amorphous alloy strip decreases monotonically from the starting radius to the target radius.

3. The method for preparing a new energy core based on amorphous alloy material according to claim 2, characterized in that, The tension value satisfies the following formula: in, The winding tension is located at a radius r from the center of the iron core. The initial tension; The inner diameter of the iron core; This is the attenuation coefficient.

4. The method for preparing a new energy core based on amorphous alloy material according to claim 1, characterized in that, The flexible polymer film is a polyimide, polyetheretherketone, or a liquid crystal polymer.

5. The method for preparing a new energy core based on amorphous alloy material according to claim 1, characterized in that, The thickness of the flexible polymer film is 10 μm–25 μm.

6. The method for preparing a new energy core based on amorphous alloy material according to claim 1, characterized in that, The process parameters for annealing are: Annealing was carried out under an inert atmosphere at a temperature of 320℃–380℃ for 1–2 hours.

7. The method for preparing a new energy core based on amorphous alloy material according to claim 1, characterized in that, The outer protective layer is made by impregnation and curing with high-temperature resistant insulating resin.

8. A new energy iron core based on amorphous alloy material, characterized in that, The new energy iron core is prepared according to the preparation method described in claim 1.

9. A new energy iron core based on amorphous alloy material according to claim 8, characterized in that, The new energy core comprises, from the inside out, an internal stress buffer layer, a main magnetic circuit functional layer, and an outer protective layer, wherein: The internal stress buffer layer is composed of alternating layers of flexible polymer film and amorphous ribbon; The main magnetic circuit functional layer is composed of stacked amorphous ribbon.

10. A new energy iron core based on amorphous alloy material according to claim 8, characterized in that, The outer protective layer is made by impregnation and curing with high-temperature resistant insulating resin.

Images