Amorphous Ribbon Magnetic Core Production via Segmented Quenching
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Solution Overview
Problem
Current methods for preparing amorphous ribbon magnetic cores face challenges in industrialization batch production due to complex processes, low production efficiency, high costs, and filament intertwining, especially for ribbons less than 1 mm in width.
Innovation Solution
A method and device utilizing single-roller rapid quenching technology with online automatic segmentation and storage, combined with air-drying, adhesive spraying, reshaping, compression, and heat-treatment to produce amorphous ribbons of controlled size and shape, enabling continuous pipeline production of magnetic cores with enhanced efficiency and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If single-roller rapid quenching technology is used to prepare amorphous ribbon with width less than 1 mm, then the ribbon can be produced, but severe involvement phenomenon occurs making industrialization batch production difficult
Solution Approach 1:
The patent applies segmentation by dividing the continuous amorphous ribbon into discrete segments through periodic pinching or cutting during the quenching process. This segmentation prevents the severe involvement phenomenon by ensuring that thin ribbons are produced as separate, manageable units rather than continuous strands that tangle and intertwine, thereby enabling industrialization batch production.
2Ease of manufacture
If Rotating Water Spinning method is used to prepare amorphous filaments, then filaments can be produced, but production efficiency is low and production cost is high
Solution Approach 1:
The patent replaces the complex rotating water spinning mechanical system with a simplified single-roller rapid quenching system. Instead of using rotating water jets and complex mechanical arrangements, the invention uses a single roller with controlled quenching to produce amorphous ribbons, significantly improving production efficiency while reducing costs.
3Ease of manufacture
If Taylor method is used to solve involvement between filaments, then on-line coiling can be achieved, but special cladding materials are needed and subsequent peeling is required
Solution Approach 1:
The patent extracts and eliminates the need for special cladding materials by using segmentation during the quenching process itself. Instead of adding extra material layers that require subsequent removal, the invention directly produces segmented amorphous ribbons without involvement, simplifying the entire process and removing unnecessary steps.
4Productivity
If amorphous broadband is used to prepare magnetic core, then production can proceed, but eddy current losses are high and comprehensive efficiency is reduced
Solution Approach 1:
The patent applies local quality by transitioning from broadband to thin-ribbon construction. The thin ribbons are locally optimized to reduce eddy current paths while maintaining overall magnetic core functionality. This local structural improvement significantly reduces eddy current losses and enhances the comprehensive efficiency of the magnetic core.
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 enables high-efficiency, low-cost continuous production of amorphous ribbon magnetic cores, improving production efficiency and product performance by streamlining the process and eliminating the need for cumbersome post-processing steps.
Implementation Method 1
it is required to quench directly from the molten state to the temperature below the freezing point at an extremely high cooling rate during the preparation process
Implementation Method 2
a cooling liquid sprinkler head is provided above the material collecting plate
Implementation Method 3
an adhesive spraying head is provided above the mould cavity
Implementation Method 4
heat-treatment to produce amorphous ribbons of controlled size and shape
Data Source
AI summary
The invention discloses a method and its device for preparing a magnetic core with amorphous ribbon. The magnetic core is prepared with amorphous ribbon, the size of the amorphous ribbon is controlled according to the target requirements, and the magnetic core with required size and shape is prepared according to the target requirements; the single-roller rapid quenching technology with online automatic segmentation and automatic storage capability is used for preparation, which can control the length, width and thickness of the amorphous ribbon according to the target requirements; the amorphous ribbon segmented by single-roller rapid quenching technology is used to spray and cool down one by one, and then air-dry, transfer, spray adhesive and online store it one by one; the stored amorphous ribbon is reshaped, compressed and heat-treated successively, and then demoulded to prepare a magnetic core.