Amorphous Alloy Lamination for Punchable Motor Core Sheets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing laminated bodies of iron-based amorphous alloy thin strips face challenges in ensuring good soft magnetic properties and efficient punch processing, particularly for high-speed rotating motors like those in EVs, due to issues such as misalignment, peeling, and difficulty in achieving sufficient thickness and adhesion.
Innovation Solution
A method involving heat treatment, application of a thermosetting resin, and thermocompression bonding of iron-based amorphous alloy thin strips with specific composition and thickness, followed by punch processing, to form a laminated body with improved adhesion and magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the thickness of iron-based silicon-boron amorphous alloy is increased to enable punch processing, then manufacturability is improved, but the thickness becomes significantly smaller than silicon steel sheet making it difficult to perform punch processing
Solution Approach 1:
The alloy is segmented into multiple thin strips (each 17-25 μm thick) that are stacked and bonded together to form a laminated body with total thickness of 50 μm or more, enabling punch processing while maintaining the advantages of thin amorphous alloy strips
Solution Approach 2:
Multiple amorphous alloy thin strips are composite-d into a laminated body structure with insulating coatings between layers, creating a composite material that combines the benefits of thin-strip amorphous alloy with the manufacturability of thicker materials
2Ease of manufacture
If phosphorus is added to increase alloy thickness, then manufacturability is improved, but saturation magnetic flux density decreases and equipment contamination occurs
Solution Approach 1:
Instead of adding phosphorus to increase thickness, the invention segments the alloy into multiple thin strips that are stacked to achieve the desired total thickness, avoiding the need for phosphorus addition and its associated problems
Solution Approach 2:
Insulating coatings serve as intermediaries between the amorphous alloy strips, enabling the stacking and bonding of multiple thin strips to achieve sufficient thickness without modifying the alloy composition with phosphorus
3Ease of manufacture
If multiple amorphous alloy thin strips are laminated to increase thickness, then punch processing becomes possible, but adhesion between strips and magnetic properties may deteriorate
Solution Approach 1:
Insulating coatings are applied as intermediaries between the amorphous alloy strips before stacking and bonding, ensuring proper adhesion between layers while preventing direct contact that could cause short circuits and maintaining magnetic properties
Solution Approach 2:
The bonding process parameters (temperature, pressure, time) are controlled within specific ranges to achieve optimal adhesion between strips without causing crystallization that would deteriorate magnetic properties
4Device complexity
If conventional lamination methods are used, then manufacturing is simplified, but misalignment and peeling occur reducing productivity
Solution Approach 1:
Insulating coatings are applied to the alloy strips before stacking and bonding, preparing the surfaces in advance to ensure proper adhesion and prevent peeling during subsequent handling and punch processing
Solution Approach 2:
The bonding temperature and pressure parameters are optimized to achieve strong adhesion between layers, preventing peeling and enabling efficient punch processing without requiring complex alignment procedures
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
Enables easy punch processing while maintaining good soft magnetic properties, suitable for manufacturing core materials for high-speed rotating motors, specifically BLDC motors for EVs, with enhanced magnetic permeability and reduced iron loss.
Implementation Method 1
an application step of applying a thermosetting resin to at least one of a plurality of the iron-based amorphous alloy thin strips after the heat treatment to form an adhesive layer; and a thermocompression bonding step of attaching and thermocompression-bonding a plurality of the iron-based amorphous alloy thin strips with the adhesive layer interposed therebetween
Implementation Method 2
a pretreatment step of subjecting a plurality of the iron-based amorphous alloy thin strips to heat treatment
Data Source
AI summary
Disclosed is a method for manufacturing a laminated body by laminating a plurality of iron-based amorphous alloy thin strips, in which the iron-based amorphous alloy thin strip is expressed by a composition formula T100-x-y-zSix(B1-mCm)yPz (where, T is at least one element selected from the group consisting of Fe, Co, and Ni and is a transition metal element necessarily containing Fe), and a thickness of the composition is 30 μm or more and 60 μm or less. The method includes: a pretreatment step S1 of subjecting a plurality of the iron-based amorphous alloy thin strips to heat treatment at a temperature of 200° C. or higher and lower than a crystallization temperature; an application step S2 of applying a thermosetting resin to at least one of a plurality of the iron-based amorphous alloy thin strips after the heat treatment to form an adhesive layer; and a thermocompression bonding step S3 of thermocompression-bonding a plurality of the iron-based amorphous alloy thin strips with the adhesive layer interposed therebetween to form the laminated body.