Laser-Marked Fe-Based Amorphous Ribbon for Lower Transformer Iron Loss
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Solution Overview
Problem
Fe-based amorphous alloy ribbons experience increased iron loss and exciting power at higher magnetic flux densities, such as 1.45 T, which is a challenge for transformer downsizing and performance optimization.
Innovation Solution
The development of an Fe-based amorphous alloy ribbon with specific laser irradiation mark configurations, including line intervals, spot intervals, and number density, which are optimized to reduce iron loss and suppress exciting power increases at higher magnetic flux densities, achieved through laser processing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional Fe-based amorphous alloy ribbons are used, then the iron loss and exciting power are acceptable at 1.3 T, but the iron loss and exciting power increase significantly at 1.45 T
Solution Approach 1:
The patent applies local quality by forming laser irradiation marks with specific patterns (line intervals of 10-60 mm, spot intervals of 0.10-0.50 mm, number density of 0.05-0.50 marks/mm²) on the surface of the amorphous alloy ribbon. These localized surface modifications create regions with altered magnetic properties that reduce eddy current losses and suppress exciting power increases at high magnetic flux densities (1.45 T), while maintaining the overall amorphous structure and bulk material properties.
Solution Approach 2:
The patent changes the surface parameters of the amorphous alloy ribbon through laser irradiation, creating specific mark configurations with controlled line intervals, spot intervals, and number densities. These parameter changes in surface structure modify the magnetic flux distribution and reduce energy losses at high operating flux densities, enabling the material to maintain stable performance at 1.45 T where conventional ribbons fail.
2Loss of energy
If laser irradiation marks are formed on the amorphous alloy ribbon surface, then iron loss is reduced at 1.45 T, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the laser irradiation process into systematic patterns with defined line intervals (10-60 mm) and spot intervals (0.10-0.50 mm), creating repetitive mark configurations across the ribbon surface. This segmentation approach standardizes the complex laser processing into manageable, repeatable units that can be controlled through programmable parameters, reducing the practical manufacturing complexity while achieving the desired iron loss reduction at 1.45 T.
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 optimized Fe-based amorphous alloy ribbon demonstrates reduced iron loss and suppressed exciting power at 1.45 T, enhancing the performance and efficiency of iron cores and transformers.
Implementation Method 1
a laser beam focused to a beam diameter of 0.5 mmφ or less, a pulsed laser beam having a beam diameter of 0.5 mmφ or less, and pulsed laser having a beam diameter of 0.3 mmφ or less and an energy density per single pulse, of from 0.02 to 1.0 J/mm2
Implementation Method 2
locally and instantaneously melting the surface of a non-crystalline alloy ribbon, then rapidly solidifying and non-crystallizing again the ribbon
Data Source
AI summary
One aspect of the invention provides an Fe-based amorphous alloy ribbon having a free solidified surface and a roll contact surface, in which the Fe-based amorphous alloy ribbon has plural laser irradiation mark rows each formed from plural laser irradiation marks on at least one surface of the free solidified surface or the roll contact surface, a line interval is from 10 mm to 60 mm, which is a centerline interval in a middle section in a width direction, between mutually adjacent laser irradiation mark rows, a spot interval is from 0.10 mm to 0.50 mm, which is an interval between center points of the plural laser irradiation marks in each of the plural laser irradiation mark rows, and the number density D (=(1/d1)×(1/d2), d1: line interval, d2: spot interval) of the laser irradiation marks is from 0.05 marks/mm2 to 0.50 marks/mm2.