Fe-Based Amorphous Ribbon With Continuous Laser Marks at 1.45 T
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Solution Overview
Problem
Conventional methods for reducing iron loss in Fe-based amorphous alloy ribbons, particularly at higher magnetic flux densities like 1.45 T, are inefficient, and existing laser scribing techniques face productivity issues and surface deformation problems, leading to suboptimal transformer performance.
Innovation Solution
The use of continuous linear laser irradiation marks formed by a CW oscillation method on the Fe-based amorphous alloy ribbon, with specific height differences and line widths, reduces iron loss and enhances the ribbon's magnetic properties, allowing for the production of ribbons with lower iron loss and improved core characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If pulse laser is used to form dotted irradiation marks to reduce iron loss, then magnetic domain segmentation is achieved, but productivity decreases and surface deformation occurs
Solution Approach 1:
The patent applies periodic action by using pulsed laser irradiation with specific duty cycles to create linear marks rather than dotted marks. The continuous linear laser irradiation marks are formed by periodic pulsing that maintains continuous coverage while allowing cooling periods, thereby achieving both iron loss reduction and improved productivity compared to traditional dotted mark methods
Solution Approach 2:
The patent implements continuity of useful action by forming continuous linear laser irradiation marks instead of discontinuous dotted marks. This continuous linear marking provides uninterrupted magnetic domain segmentation along the ribbon width, improving both the effectiveness of iron loss reduction and the productivity of the processing method
2Loss of energy
If pulse laser is used to form dotted irradiation marks, then magnetic domain segmentation is achieved, but surface deformation occurs
Solution Approach 1:
The patent uses periodic pulsed laser irradiation with optimized duty cycles to create continuous linear marks. The periodic pulsing allows for controlled heating and cooling cycles that prevent excessive surface deformation while maintaining effective magnetic domain segmentation for iron loss reduction
Solution Approach 2:
The patent applies parameter changes by optimizing laser irradiation conditions including pulse width, duty cycle, and linear mark dimensions. By controlling the height difference HL and line width WL within specific ranges, the patent achieves effective magnetic domain segmentation while minimizing surface deformation and maintaining manufacturing precision
3Loss of energy
If laser scribing is performed to reduce iron loss at higher magnetic flux densities, then magnetic properties are improved, but productivity and surface quality deteriorate
Solution Approach 1:
The patent employs periodic pulsed laser irradiation to form continuous linear marks, achieving effective iron loss reduction at high magnetic flux density (1.45 T) while maintaining high productivity through optimized pulse parameters that enable rapid processing
Solution Approach 2:
The patent optimizes laser processing parameters including pulse width, duty cycle, scanning speed, and linear mark dimensions (HL and WL) to achieve effective iron loss reduction at 1.45 T magnetic flux density while maintaining high processing speed and surface quality
4Loss of energy
If conventional laser scribing is used, then some iron loss reduction is achieved, but the reduction is insufficient at higher magnetic flux densities like 1.45 T
Solution Approach 1:
The patent applies parameter changes by optimizing laser irradiation conditions including increasing the continuity of marks (from dotted to linear), controlling height difference HL within 0.25-2.0 μm, and setting line width WL appropriately. These parameter optimizations enable effective iron loss reduction even at high magnetic flux density of 1.45 T where conventional methods fail
Solution Approach 2:
The patent implements continuity of useful action by forming continuous linear laser irradiation marks that provide uninterrupted magnetic domain segmentation. This continuous marking approach significantly improves the reliability and effectiveness of iron loss reduction at high magnetic flux densities compared to conventional discontinuous dotted marks
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 approach results in Fe-based amorphous alloy ribbons with reduced iron loss under higher magnetic flux densities, improved coercive force, and lower exciting power, enabling the creation of transformers with enhanced efficiency and reduced energy consumption.
Implementation Method 1
continuous linear laser irradiation marks formed by a CW oscillation method
Implementation Method 2
locally and instantaneously melt a surface of the amorphous alloy ribbon, and then rapidly solidifying the melted surface
Data Source
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AI summary
An Fe-based amorphous alloy ribbon reduced in an iron loss 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. The Fe-based amorphous alloy ribbon has continuous linear laser irradiation marks on at least one surface. The linear laser irradiation marks are formed along a direction orthogonal to a casting direction of the Fe-based amorphous alloy ribbon. Each linear laser irradiation mark has unevenness on its surface. When the unevenness is evaluated in the casting direction, a difference HL between a highest point and a lowest point in the thickness direction of the Fe-based amorphous alloy ribbon is 0.25 µm to 2.0 µm.