Laminated Core Sheet Orientation for Lower Iron Loss
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Solution Overview
Problem
Conventional laminated cores using non-oriented electrical steel sheets exhibit deteriorated magnetic characteristics, leading to increased iron loss and reduced performance in electrical devices like small transformers.
Innovation Solution
A laminated core configuration with specific chemical compositions and orientations of electrical steel sheets, where the laminated core's legs and yokes are aligned at 45° angles to the rolling direction, ensuring high magnetic flux density and anisotropy through controlled crystal grain growth and texture, with chemical compositions including C, Si, sol. Al, S, N, and trace elements like Mn, Ni, and controlled thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If grain-oriented electrical steel sheet is used in laminated core, then magnetic characteristics in rolling direction are improved, but magnetic characteristics in transverse direction significantly deteriorate
Solution Approach 1:
The patent changes the crystallographic orientation parameters of the electrical steel sheet by controlling the rolling direction alignment. Specifically, it orientates the <100> crystal direction at 45 degrees to the rolling direction, which transforms the magnetic anisotropy characteristics and achieves balanced magnetic performance in both rolling and transverse directions.
2Adaptability or versatility
If non-oriented electrical steel sheet with conventional composition is used, then magnetic characteristics are moderate in all directions, but iron loss increases and performance deteriorates
Solution Approach 1:
The patent optimizes the chemical composition parameters of the non-oriented electrical steel sheet by precisely controlling the content ranges of Si (1.5-4.0%), Mn (2.0-3.5%), Al (0.01-1.0%), and other elements. This compositional optimization reduces iron loss while maintaining isotropic magnetic characteristics in all directions.
Solution Approach 2:
The patent creates a composite material system by combining multiple alloying elements (Si, Mn, Al, Cr, Ni, etc.) in specific proportions within the electrical steel sheet. This multi-element composite approach achieves synergistic effects that reduce iron loss and improve overall magnetic performance compared to conventional single-element additions.
3Ease of manufacture
If conventional electrical steel sheet composition and processing is used, then manufacturing is simple, but magnetic characteristics show room for improvement
Solution Approach 1:
The patent modifies the processing parameters including cold rolling reduction rate (5-20%), finish annealing temperature (700-950°C), and annealing time (10 seconds to 1 minute) to achieve optimal crystal grain orientation and magnetic characteristics while maintaining manufacturing feasibility.
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
Improves magnetic characteristics by enhancing magnetic flux density and reducing iron loss, resulting in better performance of laminated cores.
Implementation Method 1
when B50 in a rolling direction is indicated by B50L, B50 in a direction at an angle of 90° from the rolling direction is indicated by B50C
Implementation Method 2
ensuring high magnetic flux density and anisotropy through controlled crystal grain growth and texture
Data Source
AI summary
A laminated core (100) has a plurality of legs having an extension direction in a direction perpendicular to a lamination direction of electrical steel sheets and a plurality of yokes having an extension direction in a direction orthogonal to the lamination direction of the electrical steel sheets and the extension direction of the legs, and, in the same position of the electrical steel sheet in the lamination direction, at least a partial region of the legs and at least a partial region of the yokes are configured by the same electrical steel sheet. The electrical steel sheet is disposed such that a first direction of directions of easy magnetization of the electrical steel sheet is along the extension direction of the legs and a second direction of the directions of easy magnetization of the electrical steel sheet is along the extension direction of the yokes.