Wound Core Lap Structure for Lower Iron Loss
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Solution Overview
Problem
Conventional techniques for reducing iron loss in wound cores using non-heat-resistant magnetic domain refined materials are insufficient and unsteady, as they fail to effectively address interlaminar magnetic flux transfer issues in lap portions, leading to increased iron loss and magnetic flux density waveform distortion.
Innovation Solution
The use of non-heat-resistant magnetic domain refined materials with closure domains extending in a direction intersecting the longitudinal direction, having a cross-sectional area greater than 7500 μm², and a lap length ratio of 50% or more within the range of 3.0 to 30 mm, along with a depth of 60 μm or more, to reduce interlaminar magnetic flux transfer and eddy-current loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If non-heat-resistant magnetic domain refined material is used to reduce iron loss, then iron loss can be reduced in bent portions, but interlaminar magnetic flux transfer in lap portions causes iron loss deterioration and magnetic flux density waveform distortion
Solution Approach 1:
The patent applies different magnetic domain refining approaches to different regions: non-heat-resistant treatment (laser/electron beam/plasma irradiation) is applied to bent portions where strain occurs, while heat-resistant treatment (roller projections or electrolytic etching) is applied to lap portions where interlaminar magnetic flux transfer occurs. This local differentiation allows each region to be optimized for its specific functional requirements.
Solution Approach 2:
The patent segments the core material treatment into two distinct types based on location: heat-resistant magnetic domain refined material for lap portions and non-heat-resistant magnetic domain refined material for bent portions. This segmentation allows independent optimization of each portion's magnetic properties according to its specific operational conditions.
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
This approach significantly reduces iron loss in wound cores by improving the building factor and minimizing loss in lap portions, particularly in unicore and duocore types, while maintaining a low building factor and low loss property of the material.
Implementation Method 1
magnetic domain refining treatment (non-heat-resistant type) in which strain is introduced into the surface using laser beam
Implementation Method 2
magnetic domain refining treatment (non-heat-resistant type) in which strain is introduced into the surface using laser beam, electron beam
Implementation Method 3
magnetic domain refining treatment (non-heat-resistant type) in which strain is introduced into the surface using laser beam, electron beam, or plasma irradiation
Implementation Method 4
closure domains are formed in the non-heat-resistant magnetic domain refined material so as to extend in a direction intersecting a longitudinal direction
Data Source
AI summary
Provided is a wound core having a flat portion and corner portions adjacent to the flat portion, the flat portion including a lap portion, the corner portions including bent portions. A non-heat-resistant magnetic domain refined material is used for at least a part of the materials forming the wound core. Closure domains are formed in the non-heat-resistant magnetic domain refined material so as to extend in a direction intersecting a longitudinal direction of the non-heat-resistant magnetic domain refined material, an area of each of the closure domains in a cross section that is taken in the longitudinal direction being more than 7500 μm2. In the lap portion, the ratio of the number of lap joint portions having a lap length of from 3.0 mm to 30 mm to the total number of lap joint portions is 50% or more.