Fe-Co Alloy Oxide Coating for Insulated Laminated Core Adhesion
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Solution Overview
Problem
Existing methods for forming insulation coatings on Fe-Co based alloy substrates for laminated cores require additional processes like vapor deposition, leading to increased man-hours and do not adequately address insulation, adhesion, and magnetic properties simultaneously.
Innovation Solution
A Fe-Co based alloy substrate with an oxide layer on one or both surfaces, with a thickness of 280 nm to 500 nm and a maximum interface irregularity of 300 nm or less, ensuring good insulation and adhesion while maintaining magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic layer of magnesium oxide, zirconium oxide, or aluminum oxide is formed as an insulation coating on the substrate surface, then insulation is improved, but manufacturing complexity increases due to requiring separate vapor deposition or solution application processes
Solution Approach 1:
The Fe-Co based alloy substrate itself serves as the insulating layer through controlled oxidation, eliminating the need for separate ceramic coating processes. The substrate's own oxide layer provides the insulation function,实现ing self-insulation without additional manufacturing steps.
Solution Approach 2:
By controlling the thickness of the oxide layer within 280 nm to 500 nm and managing the interface irregularity height difference to be 300 nm or less, the patent transforms the substrate surface properties to provide both insulation and adhesion functions simultaneously.
2Reliability
If an oxide layer of 0.5 μm to 10 μm is formed by oxidizing annealing, then insulation is improved, but adhesion deteriorates due to excessive thickness causing peeling
Solution Approach 1:
The patent optimizes the oxide layer thickness to 280 nm to 500 nm, which is significantly thinner than conventional 0.5-10 μm layers. This parameter change maintains sufficient insulation while preventing adhesion failure and peeling during lamination.
Solution Approach 2:
The controlled oxidation process creates an oxide layer with appropriate density and structure that provides insulation without creating the brittleness and poor adhesion associated with thicker oxide layers formed by conventional annealing.
3Strength
If the oxide layer thickness is reduced to improve adhesion, then adhesion is improved, but insulation deteriorates due to insufficient thickness
Solution Approach 1:
By precisely controlling the oxide layer thickness to 280 nm to 500 nm and managing interface irregularity height difference to be 300 nm or less, the patent achieves a balance where the thin layer provides both good adhesion and sufficient insulation performance.
Solution Approach 2:
The patent creates a uniformly thin oxide layer across the entire substrate surface with controlled interface irregularities, ensuring consistent adhesion and insulation properties throughout the material rather than having variable local properties.
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 achieves high-performance laminated core members with improved insulation, adhesion, and magnetic properties, including enhanced DC magnetic properties and corrosion resistance.
Implementation Method 1
improve electrical insulation (hereinafter also simply described as insulation) between laminated single plates
Implementation Method 2
Adhesion is also required for the Fe-Co based alloy substrate serving as a material of the laminated core, so that the insulating layer does not peel off
Data Source
Figure 1~2
Figure 3
AI summary
Provided is an Fe-Co based alloy substrate with which good magnetic characteristics can be obtained while ensuring insulation and adhesion. This Fe-Co based alloy coated substrate comprises an oxide layer on at least one of a front surface and a back surface of an Fe-Co based alloy substrate, the Fe-Co based alloy coated substrate being characterized in that: when the oxide layer is formed only on the front surface or the back surface, the thickness of the oxide layer is 280-500 nm; when the oxide layer is formed on the front surface and the back surface, the thicknesses of the oxide layers on the front surface side and the back surface side are 140-500 nm; and, in a cross section in the thickness direction of the Fe-Co based alloy coated substrate, the maximum height difference of unevenness of the oxide layer at an interface between the oxide layer and the Fe-Co based alloy substrate is 300 nm or less. A laminated core member is also provided.