Composite laminated soft magnetic ribbons with controlled physical properties

Abstract

The purpose of the present invention is to provide a composite laminated soft magnetic ribbon laminated to combine the advantages of materials and to obtain maximum efficiency as magnetic components for transformers, motor cores, etc., considering the advantages and disadvantages of individual soft magnetic ribbons such as silicon steel plate ribbons, amorphous alloy ribbons, nanocrystalline alloy ribbons, etc.　Laminated soft magnetic ribbons, which are obtained by laminating identical-width pieces of a plurality of types of soft magnetic metal ribbons having different characteristics, including amorphous alloy ribbons and nanocrystalline alloy ribbons, are laminated in a plurality of levels and subsequently secured in place to produce a magnetic component as a composite laminated soft magnetic ribbon. Magnetic components of increased width are produced from composite laminated soft magnetic ribbons obtained by: stacking a plurality of levels of laminated soft magnetic ribbons, which are obtained by laminating one or more layers in which narrow amorphous alloy ribbons and nanocrystalline alloy ribbons are placed side by side on a wide silicon steel sheet ribbon so as to yield approximately the same width as the wide silicon steel sheet ribbon; and then securing the levels in place.

Description

[Technical field]

[0001] The present invention relates to a composite laminated soft magnetic ribbon obtained by laminating soft magnetic ribbons such as silicon steel ribbon, amorphous alloy ribbon, nanocrystalline alloy ribbon, etc. The present invention relates to the manufacture of transformer cores, reactors, toroidal cores, bulk laminates, and stator cores, rotor cores, magnetic circuits, etc. for motors and generators using the composite laminated soft magnetic ribbon. [Background technology]

[0002] Amorphous alloy ribbons are produced by quenching from a molten state, and do not retain a crystal structure at the atomic level, and do not retain a specific periodic structure when examined with an electron microscope or X-ray diffraction. For this reason, amorphous alloy ribbons produced in a quenched state are usually annealed to relieve distortion at a temperature lower than the crystallization temperature, and then further softened for use. Since amorphous alloy ribbons are produced by quenching from a molten state, the width of the ribbon is about 20 cm. At present, the production and use of wider ribbons is limited. Amorphous alloy ribbons can be manufactured into soft magnetic ribbons with various characteristics, but the types generally available on the market are limited. It is known that the soft magnetic properties and core loss of amorphous alloy ribbons, which are mainly composed of normal iron, are much better than those of silicon steel sheet ribbons, etc., but the only drawback is that the magnetostriction constant is larger than that of nanocrystalline alloy ribbons and silicon steel sheet ribbons, so that the thermal contraction of the resin due to adhesion and the processing distortion are added, resulting in a deterioration of magnetic properties such as magnetic permeability and core loss.

[0003] Silicon steel ribbon, which is one type of soft magnetic ribbon, has a high saturation magnetic flux density, allowing the volume and weight of magnetic parts to be reduced. Amorphous alloy ribbon and nanocrystalline alloy ribbon have magnetic properties such as magnetic permeability and core loss that surpass those of silicon steel ribbon, making magnetic parts excellent in energy conservation. Nanocrystalline alloy ribbon has good magnetic properties including magnetostriction, so it is increasingly being used in magnetic parts, but its only drawback is its low rigidity. When magnetic parts are made optimally from amorphous alloy ribbons, the energy efficiency of transformers and motors can be increased to 97% or more, making them ideal for energy conservation. In addition, nanocrystalline alloy ribbons have low magnetostriction, so there is a high possibility that manufacturing restrictions such as processing and molding will be alleviated. Amorphous alloy ribbons and nanocrystalline alloy ribbons are generally about 0.03 mm thick, which is extremely thin compared to silicon steel sheets, and therefore have small eddy current losses. They are often used by winding and laminating. As described above, each soft magnetic ribbon has its own advantages and disadvantages, and sufficient performance cannot be obtained by constructing magnetic parts using only one of them. At present, there are almost no attempts to improve the properties by combining them with other materials, and devices are constructed using only silicon steel ribbon, amorphous alloy ribbon, or nanocrystalline alloy ribbon.

[0004] In Patent Document 1, in order to ensure the mechanical strength and rigidity that are the only drawbacks of nanocrystalline alloy laminated cores, support members are used that sandwich a non-magnetic material in the lamination direction of the laminated blocks.

[0005] In Patent Document 2, a part of an amorphous alloy ribbon that can be nano-crystallized is crystallized as a manufacturing method for a wound magnetic core, and an amorphous alloy ribbon having a similar shrinkage rate is selected, and a nanocrystalline alloy ribbon having stable properties is selected, nano-crystallized, and heat-treated to obtain stable properties.

[0006] In Patent Document 3, amorphous alloy ribbons are butted together to form large, wide amorphous alloy ribbons, which are then arranged and stacked such that the butted surfaces are offset for each lamination to produce an amorphous core transformer.

[0007] In Patent Document 4, three rolls of soft magnetic alloy ribbons are laminated into one roll by applying epoxy resin to them, and the laminate of soft magnetic alloy ribbons is bonded using two types of thermosetting resins with different glass transition temperatures.

[0008] In conventional manufacturing methods, the stator and rotor of a motor are produced by punching silicon steel sheets and laminating them. Amorphous alloy ribbons and nanocrystalline alloy ribbons are thin and hard, the lifespan of the punching dies is short, and the process of collecting, handling and laminating the punched ribbons takes time, so they are not suitable for laminating to produce a stator and rotor. In Patent Document 5, an amorphous alloy ribbon is wound into a fan shape and applied to the stator core of a motor to produce an axial gap motor, which is then applied to a fan device.

[0009] In Patent Document 6, adhesively bonded soft magnetic alloy ribbons are layered while being coated with resin, and then heated and pressed to produce a laminate. Non-Patent Document 1 examines the characteristics of a nanocrystalline alloy ribbon applied to a transformer core. Non-Patent Document 2 describes a low-loss amorphous core structure that maintains the core shape by inserting an amorphous metal foil ribbon into a resin core retainer after cutting and laminating it. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] Patent Publication No. 2021-68865 [Patent Document 2] Patent Publication No. 2021-9921 [Patent Document 3] JP 2013-98349 A [Patent Document 4] Patent Publication No. 2021-154732 [Patent Document 5] JP 2009-284578 A [Patent Document 6] JP 2007-281314 A

[0011] [Non-Patent Document 1] Kazuhiro Idei, Fumio Kurihara, Yoshinori Sunaga, "Application of next-generation nanocrystalline soft magnetic materials to transformer cores", Takaoka Technical Report, VOL.7 (2020) PP.15-18 [Non-Patent Document 2] Yuji Enomoto, Hirohiro Tokoi, Takao Imagawa, Toshifumi Suzuki, Tsuyoshi Omata, Kenichi Souma, "Amorphous Motor Achieves IE5 Level of International High Efficiency Standard," Hitachi Review, June-July 2015, pp. 50-55 Summary of the Invention [Problem to be solved by the invention]

[0012] Even with the various conventional methods, the magnetic parts produced have not been found to have sufficient characteristics. In order to solve the following problems that still exist, it is desirable to provide a method for further controlling the physical properties, laminating soft magnetic ribbons with different characteristics, and producing magnetic parts with excellent characteristics.

[0013] Although the rigidity of small nanocrystalline alloy laminated ribbons can be increased by molding, etc., the only drawback of large nanocrystalline alloy laminated ribbons is that a support member is required for the transformer core to ensure mechanical strength and rigidity. In addition, when nanocrystalline alloy laminated ribbons are used in the cores of motors and generators, noise and vibration may occur due to deformation caused by tension and repulsion due to external forces. Transformers using amorphous alloy ribbons with large magnetostriction are noisy. At present, the maximum width of ribbons that can be produced is about 20 cm for both amorphous alloy ribbons and nanocrystalline alloy ribbons. It is necessary to develop wider composite laminated soft magnetic ribbons to produce large magnetic products. Since the nanocrystalline alloy ribbons are heat-treated before lamination, they may become more brittle than before the heat treatment.

[0014] To improve the efficiency of motors, it is necessary to apply amorphous alloy ribbons and nanocrystalline alloy ribbons, which have higher magnetic permeability and lower iron loss than silicon steel sheets, to manufacture stators and rotors that are highly efficient and have good productivity.Until now, there has been no study of a method to effectively combine soft magnetic metals with different characteristics to control the physical properties and make them easy to manufacture. From the viewpoint of energy saving, magnetic products using ideal soft magnetic ribbons should be made from amorphous alloy ribbons and nanocrystalline alloy ribbons that are not subjected to processing distortion or compressive stress due to molding. Magnetic parts that are excited and used vary from low power to high power depending on the purpose of use. Magnetic bodies also include materials with low coercive force and low saturation magnetic flux density, and silicon steel plate materials with relatively high coercive force and high saturation magnetic flux density.

[0015] To reduce the volume and weight of magnetic parts using soft magnetic ribbons, silicon steel sheets with high magnetic flux density are used as the main material, but the magnetic permeability, core loss, and other properties are inferior to those of amorphous alloy ribbons and nanocrystalline alloy ribbons. For this reason, the volume and weight of magnetic parts will increase, but from the perspective of energy conservation, the development of transformers, motors, etc. that mainly use amorphous alloy ribbons and nanocrystalline alloy ribbons is progressing. To manufacture large transformers using nanocrystalline alloy ribbons, it is necessary to reinforce them with nonmagnetic supporting materials to compensate for the drawback of low rigidity. It is necessary to develop composite laminated soft magnetic ribbons that are supported and laminated with silicon steel sheets and amorphous alloy ribbons so that the nanocrystalline alloy ribbons can stand on their own without using supporting materials.

[0016] The present invention has been made in consideration of such problems, and has an object to provide a composite laminated soft magnetic ribbon that is laminated to obtain maximum efficiency by combining the advantages of materials for magnetic parts such as transformers and motor cores, taking into consideration the advantages and disadvantages of individual soft magnetic ribbons, such as silicon steel ribbons, amorphous alloy ribbons, and nanocrystalline alloy ribbons. [Means for solving the problem]

[0017] The method for manufacturing a magnetic part, which is any one of a transformer, a reactor, a toroidal core, and a motor core, according to the present invention is characterized in that a laminated soft magnetic ribbon obtained by laminating an amorphous alloy ribbon and a nanocrystalline alloy ribbon having the same width is wound multiple times and fixed to form a composite laminated soft magnetic ribbon, and a magnetic part is manufactured from the composite laminated soft magnetic ribbon.

[0018] A toroidal core made from a composite laminated soft magnetic ribbon in which the laminated soft magnetic ribbon of the present invention is wound multiple times and fixed is characterized in that the laminated soft magnetic ribbon is formed by laminating amorphous alloy ribbons and nanocrystalline alloy ribbons with the same width.

[0019] The composite laminated soft magnetic ribbon of the present invention is a composite laminated soft magnetic ribbon which is fixed after stacking multiple layers of laminated soft magnetic ribbons, and is characterized in that the laminated soft magnetic ribbon is formed by stacking one or more layers of narrow amorphous alloy ribbons and nanocrystalline alloy ribbons arranged so that the width of the narrow amorphous alloy ribbons and nanocrystalline alloy ribbons is approximately equal to the width of the wide silicon steel ribbon on top of the wide silicon steel ribbon.

[0020] The composite laminated soft magnetic ribbon of the present invention is characterized in that a laminated soft magnetic ribbon is wound multiple times around a wide silicon steel sheet ribbon, the laminated soft magnetic ribbon being made of narrow amorphous alloy ribbons and nanocrystalline alloy ribbons arranged so that their width is approximately equal to that of the wide silicon steel sheet ribbon, and then only the narrow amorphous alloy ribbons and nanocrystalline alloy ribbons arranged so that their width is approximately equal to that of the wide silicon steel sheet ribbon are wound multiple times and fixed. Effect of the Invention

[0021] By combining amorphous alloy ribbon and nanocrystalline alloy ribbon, it is possible to create magnetic parts in which the weak rigidity of the nanocrystalline alloy ribbon is reinforced by the amorphous alloy ribbon while maintaining soft magnetic properties with low iron loss. For example, a small, self-supporting, low-noise transformer can be created. If it is wound into a magnetic part, it contributes to reducing the number of work processes, and when it is used in the stator of an axial gap motor, it can be processed directly into a core. By using a laminated soft magnetic ribbon in which narrow amorphous alloy ribbons and nanocrystalline alloy ribbons are arranged on top of a wide silicon steel sheet ribbon, the amorphous alloy ribbon and nanocrystalline alloy ribbon parts can operate with a small excitation current, and by taking advantage of the large saturation magnetization of the silicon steel sheet ribbon, it is possible to create magnetic parts such as miniaturized motor stators that can operate even with a large excitation current. By winding a laminated soft magnetic ribbon that combines an amorphous alloy ribbon and a nanocrystalline ribbon around a silicon steel ribbon that is 25 cm or wider, it is possible to manufacture magnetic parts for large transformers, motors, generators, etc. with fewer work processes. [Brief description of the drawings]

[0022] [Figure 1] FIG. 1 is a diagram showing a composite laminated soft magnetic ribbon according to a first embodiment. [Diagram 2] FIG. 2 is a diagram showing a method for producing a composite laminated soft magnetic ribbon according to the second embodiment. [Diagram 3] FIG. 3 is a diagram showing the composite laminated soft magnetic ribbon produced in Example 2. As shown in FIG. [Figure 4] FIG. 4 is a diagram showing a composite laminated soft magnetic ribbon according to Example 3. In FIG. [Figure 5a] FIG. 5a is a diagram showing a method for producing a composite laminated soft magnetic ribbon according to Example 4. [Figure 5b] FIG. 5b is a diagram showing a method for producing the composite laminated soft magnetic ribbon according to the fourth embodiment. [Figure 6] FIG. 6 is a diagram showing the composite laminated soft magnetic ribbon produced in Example 4. As shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Before describing the embodiments of the present invention, the principle of the present invention will be described. Known soft magnetic ribbons include silicon steel sheets, amorphous alloy ribbons, and nanocrystalline alloy ribbons, but each has its own advantages and disadvantages in terms of magnetic properties and mechanical properties. Most magnetic parts are manufactured by laminating the same material. The best properties of each ribbon are macroscopically combined to be used as a composite laminated soft magnetic ribbon. The composite laminated soft magnetic ribbon of the present invention is constructed by holding the nanocrystalline alloy ribbon with a silicon steel sheet ribbon, an amorphous alloy ribbon, or the like, and is composed of 100% soft magnetic ribbon except for adhesive without being reinforced with a non-magnetic supporting material, which makes it possible to reduce the volume and weight of the magnetic part.

[0024] Laminated soft magnetic ribbons using amorphous alloy ribbons and nanocrystalline alloy ribbons have higher magnetic permeability than silicon steel sheets, and can be used to create magnetic parts that achieve energy savings by reducing iron loss. By using a nanocrystalline alloy ribbon as the main component of the laminated soft magnetic ribbon, it is possible to reduce magnetostriction and reduce the hum of the transformer. In addition, if the main component of the laminated soft magnetic ribbon is a nanocrystalline ribbon, the motor core may be deformed by the external force of the magnet, but the amorphous alloy ribbon is expected to increase rigidity and reduce deformation of the core. By using a laminated soft magnetic ribbon that combines the advantages of various materials rather than using one type of material, the possibility of manufacturing higher performance products is increased.

[0025] The advantages of silicon steel ribbon are its wide width and the ability to adjust the thickness as desired, but when used in composite laminated soft magnetic ribbon, it becomes possible to manufacture ribbons with widths of 25 cm or more, which will lead to the development of magnetic parts for large transformers, motors, generators, etc. By combining a magnetic material with low coercivity and a material with high saturation magnetic flux density, it is possible to create a composite material that utilizes the advantages of each material, with the material with low coercivity functioning up to its saturation magnetic flux density when the excitation energy is small, and then the material with high saturation magnetic flux density taking over when further excitation energy is applied. EXAMPLES

[0026] FIG. 1 is a diagram showing a composite laminated soft magnetic ribbon 1 according to a first embodiment. In order to improve the characteristics, a plurality of types of soft magnetic ribbons 2 having the same ribbon width but different characteristics are stacked and fixed to form a laminated soft magnetic ribbon 3. The plurality of types of soft magnetic ribbons 2 must include an amorphous alloy ribbon and a nanocrystalline alloy ribbon. A silicon steel sheet ribbon may be added as a third soft magnetic ribbon. The number of layers can be appropriately selected from about 2 to 5. The laminated soft magnetic ribbons 3 are further stacked in a plurality of layers and fixed to form a composite laminated soft magnetic ribbon 1. Although FIG. 1 shows a two-layer stack, in reality, the ribbons are stacked in about 100 layers, for example, to ensure the thickness. The fixing can be performed by an adhesive method. Nanocrystalline alloy ribbons contribute to improving the magnetic properties of magnetic parts, but when used alone, they have low rigidity and are difficult to stand on their own, and there is a possibility that they may deform when made into magnetic parts.By using them as a laminated soft magnetic ribbon by combining an amorphous alloy ribbon as a reinforcing material for the nanocrystalline alloy ribbon, the composite laminated soft magnetic ribbon can be used independently while maintaining good magnetic properties. From the viewpoint of energy saving, a composite laminated soft magnetic ribbon 1 that combines a nanocrystalline alloy ribbon and an amorphous alloy ribbon is used. The low rigidity of the nanocrystalline alloy ribbon is compensated for by the amorphous alloy ribbon, and the composite laminated soft magnetic ribbon 1 held in place can be used as a bulk laminate. Combining four rectangular parallelepipeds makes a transformer. Punching and laminating it can be used as a motor core. Since the amorphous alloy ribbon has a large magnetostriction constant, when it is made into a transformer, it vibrates with alternating current and causes noise, but if the amount of amorphous alloy ribbon used is controlled so that it is less than the nanocrystalline alloy ribbon, the vibration with alternating current can also be reduced. In Example 1, the amorphous alloy ribbon and nanocrystalline alloy ribbon are essential, but soft magnetic ribbons such as silicon steel ribbons may be used in some cases. On the other hand, in magnetic parts driven only by low current, if the magnetic parts are composed only of amorphous alloy ribbons and nanocrystalline alloy ribbons without using silicon steel ribbons, the iron loss can be significantly reduced with low coercive force, and the magnetic parts can be started with low current, which is preferable since it contributes to energy saving, although the volume and weight are somewhat large. EXAMPLES

[0027] FIG. 2 is a diagram showing a method for producing the composite laminated soft magnetic ribbon 1 according to the second embodiment. In order to improve the characteristics, multiple amorphous alloy ribbons and nanocrystalline alloy ribbons having the same ribbon width but different characteristics are stacked to form a laminated soft magnetic ribbon 3, and the laminated soft magnetic ribbon 3 is wound and then fixed to produce a composite laminated soft magnetic ribbon 1. The number of layers to be stacked can be appropriately selected from about 2 to 5. The combination of the soft magnetic ribbons 2 is selected by adjusting the thickness, such as alternating amorphous alloy ribbons and nanocrystalline alloy ribbons, or one layer of amorphous alloy ribbon and two layers of nanocrystalline alloy ribbons. If an adhesive method is used as the fixing method, the mechanical strength and rigidity can be reinforced. The composite laminated soft magnetic ribbon 1 thus produced is cut as necessary to form magnetic parts such as transformers, toroidal cores, and reactors. An amorphous alloy ribbon with a width of 2 cm wound on one reel and a nanocrystalline alloy ribbon with a width of 2 cm wound on two reels are prepared. Two layers of nanocrystalline alloy ribbon are stacked on top of the amorphous alloy ribbon and then wound. The ribbon is wound 100 times in a rectangular shape with a width of 6 cm and a length of 2 cm to produce a composite laminated soft magnetic ribbon 1 with a thickness of 1 cm as shown in Figure 3. This was used as a transformer core that has good characteristics because it uses a nanocrystalline alloy ribbon and can stand on its own without using a non-magnetic reinforcing material. A reactor, a motor core, and a bulk laminate can also be made in the same manner. The combination of soft magnetic ribbons in Example 2, like Example 1, has low hysteresis loss and eddy current loss, can reduce iron loss, has excellent soft magnetic properties, and is ideal for energy-saving magnetic parts. Currently, the stator of an axial gap motor is made by cutting and laminating an amorphous alloy ribbon and placing it in a case (Non-Patent Document 2), but it will be possible to process a cylindrical core made from the composite laminated soft magnetic ribbon 1 of Example 2, wind a coil around it, and use it as the stator of an axial gap motor. When making a core part for an axial gap motor using an amorphous alloy ribbon, the wound core is fixed by bonding and solidifying it with resin, which applies stress to the core and causes a deterioration in soft magnetic properties due to large magnetostriction, but the core part made from the composite laminated soft magnetic strip 1 of Example 2 uses a nanocrystalline alloy ribbon, which reduces the deterioration of soft magnetic properties, thereby improving the work efficiency of the manufacturing process. EXAMPLES

[0028] FIG. 4 is a diagram showing the composite laminated soft magnetic ribbon 1 according to the third embodiment. On a wide silicon steel sheet ribbon 4, narrow amorphous alloy ribbons and nanocrystalline alloy ribbons are arranged as soft magnetic ribbons 2 so that the width of the narrow amorphous alloy ribbons and nanocrystalline alloy ribbons is approximately equal to the width of the wide silicon steel sheet ribbon 4, and one or more layers are laminated to form a laminated soft magnetic ribbon 3. The laminated soft magnetic ribbon 3 is further laminated in multiple stages and fixed to form a composite laminated soft magnetic ribbon 1. The laminated soft magnetic ribbon 3 in FIG. 4 is composed of one layer each of the silicon steel sheet ribbon 4 and the soft magnetic ribbon 2, but the laminated soft magnetic ribbon 3 may be formed by laminating one layer of the silicon steel sheet ribbon and multiple layers of the soft magnetic ribbon 2. Also, FIG. 4 shows a diagram in which the laminated soft magnetic ribbons 3 are laminated in two stages to form the composite laminated soft magnetic ribbon 1, but in reality, the laminated soft magnetic ribbon 3 is laminated in, for example, about 100 stages to ensure the thickness. The composite laminated soft magnetic ribbon 1 can be processed as necessary to form magnetic parts such as motor cores, bulk laminates, generator core materials, etc. Conventionally, to manufacture a large motor core using an amorphous alloy ribbon, a single core was manufactured by connecting a plurality of teeth, which are part of the stator, in a ring shape once, but according to this embodiment, a motor core that is wider than the conventional one can be easily manufactured by one press punching. The amorphous alloy ribbon and nanocrystalline alloy ribbon parts of the composite laminated soft magnetic ribbon 1 operate with a small excitation current, and by taking advantage of the silicon steel sheet's greatest feature of high saturation magnetization, it is ideal for magnetic parts as the stator of a small motor that can make the most of miniaturization. In addition, it is suitable for magnetic parts that operate with nanocrystalline alloy ribbon and amorphous alloy ribbon at low output, and operate with silicon steel sheet ribbon with high saturation magnetization at maximum power usage, although the energy efficiency decreases at maximum power usage. When applied to a transformer, standby power consumption is reduced because it operates with nanocrystalline alloy ribbon and amorphous alloy ribbon, resulting in energy savings. Similarly, when used in a motor, it operates with nanocrystalline alloy ribbon and amorphous alloy ribbon at low output, and the silicon steel sheet ribbon part also operates at maximum output. Silicon steel ribbon has inferior soft magnetic properties compared to nanocrystalline alloy ribbon and amorphous alloy ribbon, and the drawback is that it consumes more energy. However, silicon steel ribbon has smaller magnetostriction compared to amorphous alloy ribbon, so vibrations when used in a transformer are not as large. EXAMPLES

[0029] 5a and 5b are diagrams showing a method for producing a composite laminated soft magnetic ribbon 1 according to Example 4. As shown in Fig. 5a, a silicon steel sheet ribbon 4 having a thickness of 0.1 mm, a width of 50 cm, and a length of 6 m wound on one reel, an amorphous alloy ribbon 5 having a thickness of 0.03 mm, a width of 20 cm, and a length of about 1000 m wound on two reels, and a nanocrystalline alloy ribbon 6 having a thickness of 0.02 mm, a width of 10 cm, and a length of about 1000 m wound on one reel are prepared. The ribbons are pulled out from each reel, and as shown in Fig. 5b, the amorphous alloy ribbon having a width of 20 cm, the nanocrystalline ribbon having a width of 10 cm, and the amorphous alloy ribbon having a width of 20 cm are arranged and stacked on the silicon steel sheet ribbon 4 having a width of 50 cm to form a laminated soft magnetic ribbon 3 with a total width of 50 cm, the same as that of the silicon steel sheet, and the laminated soft magnetic ribbon 3 is passed through a guide frame 7 and wound. The ribbon is wound three times, bending four places at 90 degrees each, so that the ribbon becomes a square shape with sides of 50 cm. After the silicon steel plate runs out, the 20 cm wide amorphous alloy ribbon, the 10 cm wide nanocrystalline alloy ribbon, and the 20 cm wide amorphous alloy ribbon are wound 30 times while maintaining a total width of 50 cm, and the amorphous alloy ribbon is cut when the thickness reaches 1.29 mm. If the amorphous alloy ribbon and the nanocrystalline alloy ribbon have the same thickness, the nanocrystalline alloy ribbon is also cut and the process is completed here, but in the above example, since the nanocrystalline alloy ribbon is thinner, the nanocrystalline alloy ribbon alone is continued to be wound another 15 times. After confirming that the difference between the total thickness of the amorphous alloy ribbon wound 30 times and the total thickness of the nanocrystalline alloy ribbon wound 45 times is within 0.1 mm, the nanocrystalline alloy ribbon is also cut, and the composite multilayer magnetic ribbon 1 shown in Figure 6 is produced. The cubic composite laminated magnetic ribbon 1 thus produced was fixed, and then cut at four corners to obtain four plates of 50 cm x 50 cm x 1.29 mm. Motor core materials were punched out from the plates using a press. The composite magnetic ribbon 1 according to this embodiment can also be used as a generator core. The magnetic parts such as motor cores and generator cores manufactured by this embodiment have the advantage that there is no limit to the width of the ribbon, and a wide composite soft magnetic ribbon can be used. The method according to this embodiment is suitable for manufacturing large transformer and motor cores, which require a wide width, a large thickness, and a large number of turns.

[0030] The characteristics of the magnetic components manufactured in Examples 1 to 4 can be compared and summarized as follows. The magnetic components manufactured by the methods of Examples 1 and 2 operate with low energy consumption when used at low output because the nanocrystalline alloy ribbons and amorphous alloy ribbons have low saturation magnetic flux density but excellent soft magnetic properties. Therefore, the methods of Examples 1 and 2 are suitable for magnetic components that require low output and energy saving. The magnetic components manufactured by the methods of Examples 3 and 4 necessarily use silicon steel sheet ribbons with large iron loss, which generates a lot of heat and is somewhat disadvantageous from the viewpoint of energy saving. However, at low output, the amorphous alloy and nanocrystalline alloy work to obtain a certain degree of energy saving characteristics, and at high output, even if the nanocrystalline alloy ribbon and amorphous alloy ribbon are saturated, the silicon steel sheet ribbon with high saturation magnetic flux density does not saturate and continues to operate. The methods of Examples 3 and 4 are suitable for magnetic components used over a wide range from low output to high output. In the case of producing the same magnetic parts, in the second and fourth embodiments, transformers, motor cores, etc. can be manufactured by winding and laminating. This has the advantage of realizing a reduction in the number of steps required for manufacturing magnetic parts, as compared to the first and third embodiments, which do not involve winding, and require the steps of punching and laminating. [Industrial Applicability]

[0031] According to the present invention, it is possible to manufacture magnetic parts such as bulk laminates, transformers, reactors, motor cores, and generator core materials having excellent characteristics from composite laminated soft magnetic ribbons that combine and incorporate the advantages of various soft magnetic ribbons, while reducing the number of manufacturing steps, and therefore the present invention has great industrial applicability. [Explanation of symbols]

[0032] 1. Composite laminated soft magnetic ribbon 2 Soft magnetic ribbon 3. Laminated soft magnetic ribbon 4. Silicon steel strip 5. Amorphous alloy ribbon 6 Nanocrystalline alloy ribbon 7 Guide Frame

Claims

1. A composite laminated soft magnetic ribbon which is fixed after stacking multiple layers of laminated soft magnetic ribbons, characterized in that the laminated soft magnetic ribbon is formed by stacking one or more layers of narrow amorphous alloy ribbons and nanocrystalline alloy ribbons on a wide silicon steel sheet ribbon, the layers being arranged so that the width of the narrow amorphous alloy ribbons and nanocrystalline alloy ribbons is approximately equal to the width of the wide silicon steel sheet ribbon.

2. A composite laminated soft magnetic ribbon, characterized in that a laminated soft magnetic ribbon is wound multiple times around a wide silicon steel sheet ribbon, the laminated soft magnetic ribbon being made by arranging narrow amorphous alloy ribbons and nanocrystalline alloy ribbons so that the width of the narrow amorphous alloy ribbons and nanocrystalline alloy ribbons is approximately equal to the width of the wide silicon steel sheet ribbon, and then only the narrow amorphous alloy ribbons and nanocrystalline alloy ribbons arranged so that the width of the narrow amorphous alloy ribbons and nanocrystalline alloy ribbons is approximately equal to the width of the wide silicon steel sheet ribbon, and then fixed.

3. 3. A composite laminated soft magnetic ribbon, characterized in that, when the narrow amorphous alloy ribbon and the nanocrystalline alloy ribbon as described in claim 2 do not have the same thickness, only the narrow amorphous alloy ribbon and the nanocrystalline alloy ribbon are wound multiple times, and then the thicker soft magnetic ribbon of the amorphous alloy ribbon and the nanocrystalline alloy ribbon is cut, and the other soft magnetic ribbon is further wound, and when the total thickness of the other soft magnetic ribbon becomes approximately equal to the total thickness of the thicker soft magnetic ribbon, the other soft magnetic ribbon is cut and fixed.

4. 4. A magnetic part manufactured from the composite laminated soft magnetic ribbon according to claim 1, wherein the magnetic part is any one of a transformer, a motor core, and a generator core.

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