Amorphous Magnetic Core with Organometallic Binder
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Solution Overview
Problem
Amorphous metal-based transformer cores face challenges with handling and assembly due to limited resistance to buckling, lack of self-support, and increased noise levels from magnetostriction, which lead to mechanical stresses and degradation of magnetic properties.
Innovation Solution
The method involves using an organometallic binder with a low thermal expansion coefficient, applied between amorphous metal lamination layers before thermomagnetic treatment, to create a self-supporting core structure that reduces audible noise and maintains magnetic integrity by bonding the layers together without introducing significant stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If amorphous metal lamination layers are used to manufacture transformer cores, then no-load losses are reduced, but the core becomes more susceptible to buckling and lacks self-support
Solution Approach 1:
The patent applies composite materials by combining amorphous metal lamination layers with a coating material that has different mechanical properties. The coating material forms a composite structure with the amorphous metal layers, providing buckling resistance and self-support while preserving the low no-load loss characteristics of the amorphous metal. This is achieved by applying the coating material to the edges and surfaces of the amorphous metal lamination layers, creating a hybrid structure that leverages the advantages of both materials.
2Loss of energy
If amorphous metal lamination layers are used, then core losses are minimized, but handling and assembly become difficult due to lack of rigidity
Solution Approach 1:
The patent creates a composite structure by applying a coating material to the amorphous metal lamination layers. This coating provides the necessary rigidity and structural integrity for easy handling and assembly, while the amorphous metal core maintains its low core loss properties. The composite design allows the core to be manipulated and assembled without special supporting frames, significantly improving ease of operation.
3Loss of energy
If amorphous metal cores are used, then efficiency is improved through low core losses, but noise emission increases due to magnetostriction
Solution Approach 1:
The patent employs a composite material system where the coating material is specifically selected to have low magnetostriction properties. When applied to the amorphous metal lamination layers, this coating reduces the overall magnetostriction of the core structure, thereby decreasing noise emission during transformer operation. The composite structure allows the amorphous metal to maintain its low core loss efficiency while the coating suppresses the noise-generating magnetostriction effects.
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
The solution results in a self-supporting amorphous metal magnetic core with reduced audible noise and preserved magnetic properties, ensuring mechanical stability and low no-load losses during operation.
Implementation Method 1
the thermal expansion coefficient of the film layers is lower than the a thermal expansion coefficient of lamination layers
Implementation Method 2
binding together the lamination layers with the film layers is performed by annealing the core in a magnetic field having value above 800A/m
Implementation Method 3
annealing the core in a magnetic field having value above 800A/m
Implementation Method 4
increased noise levels from magnetostriction
Data Source
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AI summary
The invention relates in general to manufacturing of an improved amorphous metal magnetic core (1) or (1') for electrical inductive apparatus such as transformers and reactors. A method of manufacturing an amorphous magnetic core comprises assembling a plurality of lamination layers (6, 6') made of amorphous metal strips to designing a core shape, having two parallel faces (9) or side surfaces (9') formed by edges of the lamination layers (6,6'). The method further comprises the step of introducing between the neighboring lamination layers (6,6') of the core (1,1') an organometallic binder (11) for receiving a number of film layers (8,8') of the binder. Next the step of binding together the lamination layers with the film layers is used by annealing the core at a temperature 350-400°C and in a magnetic field having value above 800A/m. The lamination layers (6,6') are bonded with the film layers (8,8') have capabilities for audible noise reduction when the core is under operating condition.