Fe-Based Amorphous Alloy Ribbon with CW Laser Domain Scribing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing Fe-based amorphous alloy ribbons face challenges in reducing iron loss at higher magnetic flux densities, such as 1.45 T, and suffer from productivity issues with conventional laser scribing methods, which also cause surface deformation affecting core characteristics.
Innovation Solution
The development of an Fe-based amorphous alloy ribbon with continuous linear laser irradiation marks formed using a CW oscillation method, which reduces iron loss to 0.150 W/kg or less at 1.45 T, while maintaining high productivity and minimizing surface deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional laser scribing methods are used to segment magnetic domains, then iron loss is reduced, but productivity decreases and surface deformation occurs
Solution Approach 1:
The patent changes the laser oscillation method from conventional pulsed laser to CW (continuous wave) oscillation method. This parameter change in laser operation mode enables continuous linear irradiation marks instead of discrete spots, significantly improving processing speed and productivity while maintaining the magnetic domain segmentation effect that reduces iron loss
Solution Approach 2:
The patent implements continuous linear laser irradiation marks by using CW oscillation method, creating uninterrupted linear traces across the ribbon surface. This continuous action covers the entire surface area efficiently, segmenting magnetic domains throughout the material without the gaps inherent in pulsed methods, thereby reducing iron loss while maintaining high productivity
2Loss of energy
If laser scribing is applied to reduce iron loss, then magnetic domain segmentation is achieved, but surface deformation affects core characteristics
Solution Approach 1:
The patent modifies the laser processing parameters by using CW oscillation method with controlled linear density (5-35 J/m). This parameter control allows the laser energy to be distributed continuously along linear paths, achieving magnetic domain segmentation while minimizing localized thermal effects that cause surface deformation and embrittlement
Solution Approach 2:
The patent creates localized linear irradiation marks with specific width (28-90 μm) and linear density parameters. These locally optimized parameters ensure sufficient energy for magnetic domain segmentation while limiting the affected zone to prevent excessive surface deformation and maintain core characteristics
3Loss of energy
If iron loss is reduced at higher magnetic flux densities, then transformer efficiency improves, but existing materials fail to achieve target loss levels
Solution Approach 1:
The patent optimizes the laser processing parameters including linear density (5-35 J/m), mark width (28-90 μm), and spacing to achieve effective magnetic domain segmentation. These parameter optimizations enable the material to maintain excellent magnetic characteristics while achieving iron loss of 0.150 W/kg or less at 1.45 T, meeting both performance and reliability requirements
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 proposed solution achieves significant reduction in iron loss and exciting power, while ensuring excellent magnetic characteristics and high productivity, making it suitable for high-frequency applications.
Implementation Method 1
a method of segmenting the magnetic domain of the Fe-based amorphous alloy ribbon by irradiating a surface of the Fe-based amorphous alloy ribbon with a laser light to locally melt and rapidly solidify the surface
Implementation Method 2
locally melt and rapidly solidify the surface
Data Source
AI summary
An Fe-based amorphous alloy ribbon reduced in iron loss, less deformed, and highly productive in a condition of a magnetic flux density of 1.45 T is provided. One aspect of the present disclosure provides an Fe-based amorphous alloy ribbon having first and second surfaces, and is provided with continuous linear laser irradiation marks on at least the first surface. Each linear laser irradiation mark is formed along a direction orthogonal to a casting direction of the Fe-based amorphous alloy ribbon, and has unevenness on its surface. When the unevenness is evaluated in the casting direction, a height difference HL×width WA calculated from the height difference HL between a highest point and a lowest point in a thickness direction of the Fe-based amorphous alloy ribbon and the width WA which is a length of the linear irradiation mark on the first surface is 6.0 to 180 μm2.