Laminated Amorphous Alloy Ribbon Laser Marking for Low Iron Loss
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Solution Overview
Problem
The existing methods for producing laminated amorphous alloy ribbons for iron cores, such as those used in transformers, face challenges in achieving high productivity and wide market acceptance due to inefficiencies in laser irradiation and lamination processes, leading to suboptimal iron loss, coercive force, and exciting power performance.
Innovation Solution
A method involving the production of laminated amorphous alloy ribbon holding spools through simultaneous laser irradiation and lamination of single layer ribbons, with controlled traveling and scanning speeds, laser output energy density, and linear mark formation, enabling efficient and high-performance ribbon production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If laser irradiation is applied to amorphous alloy ribbon to improve magnetic properties, then iron loss and coercive force are reduced, but productivity decreases due to sequential processing requirements
Solution Approach 1:
The patent combines laser irradiation and lamination processes into a single integrated operation. Multiple ribbons are laminated together while simultaneously receiving laser irradiation, merging what were previously separate sequential steps into one concurrent process that improves productivity without sacrificing the magnetic property improvements
Solution Approach 2:
The patent implements continuous laser irradiation throughout the lamination process rather than treating them as discrete steps. The laser beam continuously irradiates the ribbons as they are being laminated, maintaining useful action throughout the entire process duration and eliminating idle time between operations
2Loss of energy
If multiple single layer ribbons are laminated to form high-performance laminated ribbons, then magnetic properties improve, but the production process becomes complex and less efficient
Solution Approach 1:
The patent merges the lamination of multiple ribbons with laser irradiation into a single integrated process. Instead of laminating ribbons separately and then irradiating them in subsequent steps, both operations occur simultaneously, reducing process complexity while achieving the same magnetic property improvements
Solution Approach 2:
The laser irradiation system is designed to handle multiple ribbons simultaneously during lamination, making the processing system multi-functional. A single processing step accomplishes both the bonding of multiple ribbons and the magnetic property modification, reducing overall process complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances productivity and achieves low iron loss, coercive force, and exciting power, making high-performance laminated amorphous alloy ribbons suitable for efficient iron core production.
Implementation Method 1
a laser scribing method comprising radiating a laser beam to a surface of the amorphous alloy ribbon to locally melt the surface and rapidly solidify the ribbon
Implementation Method 2
locally melt the surface and rapidly solidify the ribbon
Implementation Method 3
the amorphous alloy ribbon, which has rapidly solidified on a surface of a cooling roll
Data Source
AI summary
A method of producing a laminated amorphous alloy ribbon holding spool. The method includes providing amorphous alloy ribbon holding spools, each of which is wound with a single layer amorphous alloy ribbon, unwinding the single layer amorphous alloy ribbon from each of the amorphous alloy ribbon holding spools, making the single layer amorphous alloy ribbon travel with a laser being radiated thereto, to thereby simultaneously prepare single layer amorphous alloy ribbons having laser irradiation mark formed thereon, laminating the single layer amorphous alloy ribbons having the laser irradiation mark formed thereon to, thereby prepare a laminated amorphous alloy ribbon, and winding up the laminated amorphous alloy ribbon on a spool.