Cu-Scattered Alloy Ribbon for Adhesive Magnetic Core Stacking
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Solution Overview
Problem
Fe-based nanocrystal alloy ribbons used in magnetic cores have poor adhesiveness and surface followability, leading to decreased magnetic properties when stacked, and existing methods to improve adhesiveness, such as surface roughening, compromise magnetic performance.
Innovation Solution
An alloy ribbon with scattered metals of 1 μm or more in diameter, including Cu, with a Vickers hardness of 900 Hv or more, and a surface roughness of 1.0 μm or less, scattered at a frequency of 1 to 4,500 metal/mm², which improves adhesiveness between ribbons while maintaining magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the surface of the alloy ribbon is roughened to improve adhesiveness, then adhesiveness between alloy ribbons improves, but surface factor decreases and magnetic properties deteriorate
Solution Approach 1:
The invention applies local quality by scattering metal particles specifically on the surface of the alloy ribbon rather than roughening the entire surface. This localized modification provides adhesiveness enhancement at the contact points while preserving the overall smooth surface quality and magnetic properties of the ribbon.
Solution Approach 2:
The scattered metal particles act as an intermediary substance between the alloy ribbon surfaces. These particles create mechanical interlocking and chemical bonding sites that improve adhesiveness without requiring the alloy ribbon surface itself to be roughened, thus maintaining magnetic properties.
2Reliability
If Fe-based nanocrystal alloy is produced by super quenching to improve saturation magnetic flux density, then magnetic properties improve, but adhesiveness and surface followability become poor
Solution Approach 1:
The scattered metal particles are prepared and positioned on the alloy ribbon surface in advance, before the stacking and pressing process. This preliminary action ensures that the adhesiveness enhancement is already in place before the ribbons are assembled, allowing the inherent magnetic properties of the nanocrystal alloy to be fully utilized without compromise.
3Strength
If resin coating and drying procedures are added to improve adhesiveness, then adhesiveness between alloy ribbons improves, but production complexity increases
Solution Approach 1:
The invention extracts the adhesiveness enhancement function from the complex multi-step resin coating and drying process, achieving the same effect through a simpler method of scattering metal particles during or after ribbon production. This eliminates the need for separate coating and drying equipment and procedures.
Solution Approach 2:
The scattered metal particles on the alloy ribbon surface provide self-adhesiveness enhancement without requiring external resin materials or drying processes. The metal particles themselves create the bonding mechanism through mechanical interlocking and potential metallurgical bonding during pressing.
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 enhances adhesiveness between alloy ribbons, suppresses the increase of coercive force, and improves magnetic properties under high frequency bands, resulting in a more effective magnetic core with reduced AC magnetic loss.
Implementation Method 1
By roughening the surface of the alloy ribbon, it is known that an adhesiveness between alloy ribbons improve due to an anchor effect.
Implementation Method 2
a Fe-based amorphous alloy, a Fe-based nanocrystal alloy, and the like are used from the point of improving a saturation magnetic flux density
Data Source
AI summary
The object of the present invention is to provide an alloy ribbon capable of having excellent adhesiveness between the alloy ribbons when a plurality of the alloy ribbons is stacked; and also, to provide a magnetic core using the alloy ribbon. The present invention is an alloy ribbon comprising metals scattered on at least one surface of the alloy ribbon, in which diameters of the scattered metals are 1 μm or more, and the scattered metals include Cu.