Iron-Based Amorphous Alloy Strip for High Flux Density
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Solution Overview
Problem
Fe—B—Si-based amorphous alloy thin strips used in wound iron cores face challenges in achieving high magnetic flux density while maintaining low iron loss, as higher Fe content compromises stability and increases iron loss when transformed into a wound core.
Innovation Solution
An iron-based amorphous alloy thin strip with a chemical composition of FexBySiz (x = 78-83 at%, y = 8-15 at%, z = 6-13 at%) and controlled surface properties, including limited air pockets and specific additions of Cr, Mn, C, P, Sn, and Sb, to enhance magnetic flux density and reduce iron loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the Fe content in the amorphous alloy is increased to enhance saturated magnetic flux density, then the magnetic flux density is improved, but the amorphous stability is reduced and iron loss increases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters (Fe: 78-83 at%, B: 8-15 at%, Si: 6-13 at%) and physical parameters (air pocket number: ≤8 pockets/cm², air pocket length: ≤0.5 mm) to achieve the optimal balance between magnetic flux density and amorphous stability. This resolves the contradiction by finding the specific parameter range where both high magnetic flux density and stable amorphous structure coexist.
Solution Approach 2:
The patent uses composite material principles by combining multiple alloying elements (Fe, B, Si, Cr, Mn, C, P, Sn, Sb) in specific proportions to create a multi-element amorphous alloy system. This composite approach allows the material to achieve both high magnetic flux density through Fe content while maintaining amorphous stability through the synergistic effects of B, Si, and other stabilizing elements.
2Illumination intensity
If the Fe content in the amorphous alloy is increased to enhance saturated magnetic flux density, then the magnetic flux density is improved, but the iron loss in the wound iron core is increased
Solution Approach 1:
The patent resolves this contradiction by changing multiple parameters simultaneously: optimizing Fe content to 78-83 at% for high magnetic flux density while controlling air pocket density (≤8 pockets/cm²) and size (≤0.5 mm length) to minimize eddy current losses. The addition of specific elements (Cr: 0.2-1 at%, Mn: 0.2-2 at%) further refines the balance between magnetic performance and energy loss.
3Illumination intensity
If the Fe content in the amorphous alloy is increased to enhance saturated magnetic flux density, then the magnetic flux density is improved, but the transformer size increases and more copper wire is required
Solution Approach 1:
The patent achieves high magnetic flux density (resolving the transformer size issue) by optimizing the Fe content to 78-83 at% while simultaneously controlling the air pocket characteristics (number ≤8 pockets/cm², length ≤0.5 mm). This parameter optimization ensures that the material can operate at higher flux densities without increasing transformer size, as the controlled air pocket structure prevents excessive magnetic losses that would require larger dimensions.
4Ease of manufacture
If the surface property of the thin strip is not controlled, then the manufacturing process is simpler, but the iron loss increases during working to a wound iron core
Solution Approach 1:
The patent resolves this contradiction by establishing specific surface property parameters (air pocket number ≤8 pockets/cm², air pocket length ≤0.5 mm) that can be controlled during the rapid solidification process. These parameter specifications provide clear manufacturing targets that balance the ease of production with the requirement to minimize iron loss in the final wound core product.
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 stabilizes high magnetic flux density and low iron loss in wound iron cores, reducing the need for larger transformers and less copper wire, while minimizing the 'building factor' of iron loss during transformation.
Implementation Method 1
injecting a iron-based molten alloy based on Fe and added with B, Si and the like onto a surface of a high-speed rotating cooling roll to perform rapid solidification
Data Source
AI summary
A iron-based amorphous alloy thin strip having a chemical composition represented by a chemical formula of FexBySiz (wherein x is 78-83 at %, y is 8-15 at % and z is 6-13 at %), wherein the number of air pockets at a surface contacting with a cooling roll is not more than 8 pockets/mm2 and an average length in a circumferential direction of the roll is not more than 0.5 mm.