JP4816444B2 - SOFT MAGNETIC MAGNETIC MEMBER, SOFT MAGNETIC MAGNETIC MEMBER LAMINATE AND METHOD FOR PRODUCING THEM - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a soft magnetic magnetic member such as a magnetic steel sheet employed in a rotating electrical machine or a stationary magnetic device and a laminate formed by laminating the same, and in particular, a soft magnetic magnetic member having low eddy current loss characteristics and a method for manufacturing the same. About.

  In order to reduce the heat generation and improve the efficiency of rotating electrical machines and stationary magnetic equipment, it is required to reduce the eddy current loss of the soft magnetic magnetic members that make up the magnetic circuit, especially when high-frequency power is supplied. Will be serious. For example, Patent Document 1 below describes a method for manufacturing this type of electrical steel sheet with an insulating coating.

  For this reason, conventionally, an electromagnetic steel sheet with an insulating coating coated with an insulating coating agent on the surface and subjected to a baking process is laminated and used. Furthermore, for high frequency applications, resin molded products mixed with various soft magnetic powders are used. For example, Patent Document 2 below describes this type of soft magnetic powder-containing resin molded product (hereinafter also referred to as a dust core or a powder core).

  Various methods have been conventionally used as a method for producing an insulating coating to be applied to an electromagnetic steel sheet. In general, it is the mainstream to apply an inorganic coating agent mainly composed of phosphate or chromate, but an inorganic-organic coating agent in which an organic resin is added and blended based on chromate is used. In some cases, an organic component-based coating agent may be used. These coating agents are usually heated (baked in) after coating. In addition to the electrical insulation between the electromagnetic steel sheets, the insulating coating also exhibits an adhesion function between the electromagnetic steel sheets by a thermocompression bonding process in which the laminated electromagnetic steel sheets are compressed while being heated.

  For such an application, for example, a mixed liquid mainly composed of an acrylic modified epoxy resin emulsion blended with a latent curing agent is applied and burned incompletely. It is preferable to employ Patent Document 3). Further, when an amorphous alloy ribbon laminated plate (Patent Document 4) is produced instead of the electromagnetic steel sheet, if the amorphous alloy ribbon is laminated by applying a heat-resistant adhesive, it is 350 ° C. or higher. It is also known that the bonding ability does not decrease even if annealing is performed in a high temperature magnetic field.

Furthermore, the following patent document 5 proposes to apply and bake a heat-resistant resin film mainly composed of a thermoplastic siloxane polymer. Since this heat-resistant resin film has good heat resistance, it is said that even if it is subjected to strain relief (650 ° C. or higher and 850 ° C.) after the resin film is applied, its adhesive state and electrical insulation can be maintained. The inorganic polymer is a polymer in which a main skeleton is constituted by inorganic bonds of M (metal or semimetal) -O (oxygen) -M. When M is Si, the Si—O bond is called a siloxane bond. In addition, the siloxane polymer referred to in Patent Document 5 means a polymer whose inorganic components are composed only of Si and O, and Patent Document 5 describes that a certain siloxane polymer has good thermoplasticity suitable for a magnetic steel sheet coating agent. It is described.
JP-A-5-65663 JP-A-6-176946 Japanese Patent No. 2613725 International Publication WO 86/05314 JP 2006-54244 A (P2006-54244A)

  However, the above-mentioned electrical steel sheet has a relatively large eddy current loss, and particularly has a drawback that the eddy current loss increases rapidly when the frequency of the feed power is increased. For this reason, although the thickness is reduced, there is a limit to this, and the eddy current loss reduction effect by reducing the thickness of the electromagnetic steel sheet is also limited. In addition, when it is necessary to form the magnetic circuit three-dimensionally, there is a problem that eddy current loss increases rapidly because magnetic flux must flow in the thickness direction of the laminated electrical steel sheet.

  On the other hand, the dust core can remarkably reduce eddy current loss as compared with laminated magnetic steel sheets, and can avoid a sudden increase in eddy current loss even when a magnetic flux is flowed three-dimensionally. Since the density is much smaller than electromagnetic steel sheets, there is a drawback that the equipment size is greatly increased to obtain the same output, and further, the manufacturing process is much more complicated than electromagnetic steel sheets and the cost is high. there were. Furthermore, there is a problem that it is difficult to carry out the strain relief annealing process in the temperature range of 700 to 800 ° C. for improving the magnetic characteristics.

  The present invention has been made in view of the above problems, and has an eddy current loss much smaller than that of a soft magnetic magnetic member made of a conventional laminated electrical steel sheet, and is softer at a much lower cost than a conventional dust core. It is an object of the present invention to provide a soft magnetic magnetic member having excellent practicality as a magnetic magnetic member, a laminate of soft magnetic magnetic members, and a method for producing them.

First invention for solving the above-mentioned problems, a soft magnetic metal material in soft magnetic member formed in a plate shape as a material, the first arrangement direction perpendicular to the thickness direction together when made of a soft magnetic metal material A plurality of soft magnetic strips arranged in parallel to each other at a predetermined pitch and arranged in a second arrangement direction perpendicular to the plate thickness direction, and attached to or formed on the surface of the soft magnetic strips And an inorganic insulating film that increases an electrical resistance value between the soft magnetic strip portions, and the soft magnetic strip portions are mechanically coupled to each other through the insulating film and formed into a plate shape. The insulating film is located between the soft magnetic strip portions adjacent to each other, and is arranged at a predetermined pitch in each of the first arrangement direction and the second arrangement direction. Yes.

That is, the soft magnetic strip portion of the present invention is formed by dividing the soft magnetic plate in two directions substantially perpendicular to the plate thickness direction, and has a three-dimensional shape (for example, a dice shape) having six planes. In this way, a good eddy current loss reduction effect can be achieved with respect to the magnetic flux in any direction of the three-dimensional space.

  Preferably, an insulating coating similar to the conventional one is also provided on the surface perpendicular to the plate thickness direction of each soft magnetic strip, and this insulating coating is formed in the same process as the insulating coating provided on the cut surface. Is preferable. Moreover, although it is suitable for each soft-magnetic strip part to adhere | attach with the said insulating film, you may employ | adopt another mechanical coupling | bonding means. As an insulating film, the insulating film employ | adopted as the above-mentioned conventional electromagnetic steel plate can be employ | adopted. In addition, the width | variety and length of a soft-magnetic strip part are free, and one soft-magnetic strip part can be formed in tape shape, or can be formed in dice shape. The former can improve the magnetic characteristics in one direction compared to the latter, and the latter can improve the effect of reducing eddy current loss in each of the three-dimensional directions compared to the former. The insulating coating may be performed before or after annealing the soft magnetic strip portion. Further, after forming the soft magnetic strip portion from the soft magnetic plate, annealing may not be performed, and the soft magnetic plate before forming the soft magnetic strip portion may be annealed.

  According to the present invention, the effect of reducing the eddy current loss with respect to the alternating magnetic flux in the thickness direction can be greatly improved as compared with the conventional electromagnetic steel sheet, and the perpendicular direction to the thickness direction compared with the conventional electromagnetic steel sheet. Even when alternating magnetic flux flows in the direction, the eddy current loss can be reduced because the electrical resistance value of the eddy current circuit can be increased.

  In a preferred aspect, the first arrangement direction and the second arrangement direction are orthogonal to each other. If it does in this way, manufacture and manufacture of the soft magnetic member of a required shape after that become easy.

A second invention is a method of manufacturing a soft magnetic magnetic member formed in a plate shape from a soft magnetic metal material, wherein the soft magnetic magnetic member is made of a soft magnetic metal material and at least perpendicular to the plate thickness direction. A plurality of soft magnetic strips arranged at a predetermined pitch in a predetermined arrangement direction, and an electric resistance value between the soft magnetic strips formed on the surface of the soft magnetic strips. An inorganic insulating film to be increased, and the soft magnetic strip portions are mechanically coupled to each other through the insulating film and formed into a plate shape, each formed in a long shape, and A first step that extends in a plate thickness direction and an extending direction perpendicular to the arrangement direction, and cuts the electromagnetic steel sheet into a predetermined width to form the strip-shaped soft magnetic strip portion; The insulating film is deposited on at least the cut surface of the strip-shaped soft magnetic strip. And a second step of forming a third step of mechanically coupled together soft magnetic strip of a number of the strip through the insulating film, and formed by cutting the magnetic steel sheets to a predetermined width The strip-shaped soft magnetic strip portion is displaced by a predetermined distance relative to the adjacent strip-shaped soft magnetic strip portion in the thickness direction, and then the insulating film is deposited or formed. After that, the displacement is canceled, and then the mechanical coupling is performed. In this way, the soft magnetic magnetic member of the present invention can be manufactured with excellent productivity by a continuous process.

A third invention is a method for producing a soft magnetic magnetic member formed in a plate shape from a soft magnetic metal material, wherein the soft magnetic magnetic member is made of a soft magnetic metal material and at least perpendicular to the thickness direction. A plurality of soft magnetic strips arranged at a predetermined pitch in a predetermined arrangement direction, and an electric resistance value between the soft magnetic strips formed on the surface of the soft magnetic strips. An inorganic insulating film to be increased, and the soft magnetic strip portions are mechanically coupled to each other through the insulating film and formed into a plate shape, each formed in a long shape, and It extends in the plate thickness direction and the extending direction perpendicular to the arrangement direction, and conveys a long electromagnetic steel sheet in a predetermined conveying direction, and at the upstream portion in the conveying direction, the electromagnetic 1st which cuts a steel plate by predetermined width and forms a strip-shaped soft-magnetic strip part The second step of depositing or forming the insulating film on at least the cut surface of the strip-shaped soft magnetic strip portion at the midstream portion in the transport direction is performed, and a number of the strip-shaped portions are formed at the downstream portion in the transport direction In the method of manufacturing a soft magnetic member that performs the third step of mechanically coupling the soft magnetic strips of each other through the insulating film, the long electromagnetic steel plate (including the tape-shaped soft magnetic plate) As the movement in the conveyance direction, the magnetic steel sheet is cut in the conveyance direction to form the soft magnetic strip portion in a strip shape. In this way, it is possible to easily form the soft magnetic strip portion by cutting.

According to a fourth aspect of the present invention, there are provided a plurality of soft magnetic strip portions made of a soft magnetic metal material and arranged at a predetermined pitch in a predetermined arrangement direction perpendicular to the plate thickness direction, and on the surface of the soft magnetic strip portion. An inorganic insulating film that is deposited or formed to increase the electrical resistance between the soft magnetic strip portions, and the soft magnetic strip portions are mechanically coupled to each other through the insulating film. the soft magnetic member is formed plate-shaped with a large number to form a stack of formed by laminating a thickness direction soft magnetic member. The laminated body of soft magnetic members formed in this way can greatly improve the effect of reducing eddy current loss with respect to the alternating magnetic flux in the thickness direction compared to conventional laminated electromagnetic steel sheets. Even when alternating magnetic flux flows in the direction perpendicular to the thickness direction, the eddy current loss can be reduced because the electric resistance value of the eddy current circuit can be increased.

  In a preferred embodiment, the insulating films of the two laminated plate-like soft magnetic members extend in different directions. That is, in this aspect, the soft magnetic strips of the two soft magnetic members to be stacked extend in different directions. In this way, at a low magnetic flux amount, the magnetic resistance of the laminate can be reduced by allowing the magnetic flux to flow through a plate-like soft magnetic magnetic member in which no insulating film is arranged in the magnetic flux direction. Even if the amount of magnetic flux increases, the average magnetic resistance in each direction can be reduced. Furthermore, the strength in each direction of the laminate can also be improved.

  In a preferred aspect, the extending direction of the insulating film of at least one of the two plate-like soft magnetic members is set substantially in the magnetic flux passing direction. If it does in this way, the mechanical strength of a layered product can also be improved, reducing the magnetic resistance of a magnetic flux passage direction.

  In a preferred embodiment, the extending directions of the insulating films of the two plate-like soft magnetic members are orthogonal to each other. In this way, the magnetic resistance and eddy current loss in each of the three-dimensional directions can be reduced, and the mechanical strength can be improved.

  In a preferred embodiment, the magnetic circuit is configured by combining with a soft magnetic member other than the laminate of the soft magnetic members. In this way, a complicated three-dimensional magnetic circuit can be configured with low eddy current loss. In addition, what is necessary is just to select a powder magnetic core, a normal laminated electromagnetic steel plate, etc. according to a desired request | requirement as soft magnetic magnetic members other than the laminated body of the soft magnetic magnetic member of this invention, for example.

  In a preferred embodiment, the laminated body of soft magnetic magnetic members is formed by cutting a laminated body of soft magnetic magnetic members such as electromagnetic steel plates (or soft magnetic amorphous alloy tapes) to a predetermined width. A first step of forming a laminate of pieces, a second step of depositing or forming the insulating film on at least a cut surface of the laminate of strip-like soft magnetic strips, and a number of the strip-like soft magnetism And a third step of mechanically coupling the laminated body of the thin piece portions to each other through the insulating film to form the laminated body of the soft magnetic magnetic members. In other words, in this embodiment, a soft magnetic magnetic member laminate prepared in advance is divided to form a large number of soft magnetic strip portions in the same manner as described above, and an insulating film is provided on at least a sectional surface to provide a soft magnetic strip. Therefore, the laminated body of soft magnetic members can be manufactured with high productivity.

  In a preferred embodiment, the cut surface of the laminate of the soft magnetic magnetic members is formed in a direction perpendicular to the lamination direction. Thereby, the frequency | count of cutting | disconnection can be reduced.

  In a preferred embodiment, a large number of the soft magnetic magnetic members are sequentially cut into a predetermined planar shape, and the cut soft magnetic magnetic members are sequentially stacked to form a laminate of soft magnetic magnetic members having a predetermined three-dimensional shape. To do. In this way, cutting becomes easy.

  Preferred embodiments of the soft magnetic member of the present invention, a laminate thereof, and a production method thereof will be described below. However, the present invention should not be construed as being limited to the following embodiments, and it goes without saying that the technical idea of the present invention may be realized by combining other known techniques. In the following embodiment, an example in which a soft magnetic magnetic member is produced using a normal electromagnetic steel sheet as a raw material is described. However, a soft steel sheet or a soft magnetic amorphous alloy sheet may be used instead of a normal electromagnetic steel sheet. .

(Embodiment 1)
The soft magnetic magnetic member and the manufacturing method thereof according to Embodiment 1 will be described below. This soft magnetic magnetic member is formed in a flat plate shape like a conventional electromagnetic steel plate. Of course, for handling, this plate-like soft magnetic member can be wound into a roll. A manufacturing process diagram of the soft magnetic magnetic member shown in FIG. 1 will be described.

  First, a soft magnetic thin plate (for example, a plate thickness of 0.5 mm) 1 such as an electromagnetic steel plate is prepared. The thin plate 1 may be in the form of a roll (step a). The insulating coating described above is applied to the surface of the thin plate 1.

  Next, the thin sheet 1 of the electromagnetic steel sheet is cut in the width direction at a predetermined pitch (for example, 1 mm pitch) in the length direction to form a large number of soft magnetic strip portions 2 (step b). The cutting is preferably performed in the thickness direction, but is not limited thereto. Thereafter, an insulating film is deposited on at least the cut surface of each soft magnetic strip portion 2. This insulating film can be formed by the same method as the above-described insulating coating of the electromagnetic steel sheet, or can be formed by using, for example, a known CVD method or PVD method. In addition, the soft magnetic strip portion 2 may be immersed in a tank filled with a resin liquid and dried to deposit the resin insulating film.

  Next, the soft magnetic strips 2 are arranged in the length direction, extend in the width direction, and are thermocompression bonded in the length direction to form the soft magnetic member 3 (step c).

  In this way, a soft magnetic magnetic member with low eddy current loss can be realized. The soft magnetic magnetic member is formed into a predetermined shape by punching or the like, and then laminated in the thickness direction as in the prior art to form a laminated body of soft magnetic magnetic members having a desired shape.

  According to the plate-like soft magnetic member 3 of this embodiment, the effect of reducing the eddy current loss with respect to the alternating magnetic flux in the plate thickness direction can be greatly improved as compared with the conventional electromagnetic steel plate, and the conventional electromagnetic Compared with a steel plate, the eddy current loss can be reduced because the electric resistance value of the eddy current circuit can be increased even when an alternating magnetic flux flows in a direction perpendicular to the plate thickness direction. An insulating film can also be employed as the insulating film.

  In addition to the above-described linear parallel arrangement, each soft magnetic strip portion can also be arranged in parallel with a polygonal line, a wavy line, or other curved lines, and various arrangements such as a square lattice arrangement, a checkered arrangement, etc. Further, combinations thereof are also free. In addition, the soft magnetic strip portions may be arranged at unequal pitches, and the boundary lines between the soft magnetic strip portions may not be parallel to each other. Some examples of the above-described various soft magnetic strip portion arrangement methods are shown in FIGS. 2A to 2F, the broken lines indicate the boundary portions of the soft magnetic strip portions.

(Embodiment 2)
The soft magnetic magnetic member and the manufacturing method thereof according to Embodiment 2 will be described below. This soft magnetic magnetic member is formed in a flat plate shape like a conventional electromagnetic steel plate. Of course, the plate-like soft magnetic member 3 can be wound up for handling. With reference to FIG. 3 showing a schematic perspective view of the soft magnetic member, the soft magnetic member of this embodiment will be described.

  This soft magnetic member 3 is formed by forming a large number of dice-shaped soft magnetic strips 2 obtained by cutting a number of electromagnetic steel sheets at predetermined pitches in two directions perpendicular to the plate thickness direction and perpendicular to each other. An insulating film is formed on at least the cut surface of the magnetic strip portion 2, and then each soft magnetic strip portion 2 is thermocompression bonded to produce a flat soft magnetic member. As a manufacturing process, it can manufacture by the same method as the manufacturing process of Embodiment 1 shown in FIG. 1 except having implemented the process (b) shown in FIG. 1 twice continuously, changing the cutting direction.

  In FIG. 3, 4 indicates the first cutting direction, and 5 indicates the second cutting direction. The cutting direction may not be perpendicular to the plate thickness direction, and the two cutting directions 4 and 5 may not be perpendicular to each other. In this way, a soft magnetic magnetic member with low eddy current loss can be produced.

(Embodiment 3)
The soft magnetic magnetic member and the manufacturing method thereof according to Embodiment 3 will be described below. This soft magnetic member is suitable for manufacturing the soft magnetic member 3 of the first embodiment. The manufacturing process of this soft magnetic member will be described with reference to FIG. 4 which is a schematic process diagram. As described above, other soft magnetic plates may be used instead of electromagnetic steel plates.

  The manufacturing apparatus has a conveying device (not shown) that conveys the long electromagnetic steel sheet 100 in the longitudinal direction, and the electromagnetic steel sheet moves the long electromagnetic steel sheet 100 in the interval from the upstream side to the downstream side in the conveying direction. Done. Further, this manufacturing apparatus includes a cutting device 6, a shift device (not shown), an insulating film processing device (not shown), a shift canceling device (not shown), and a heat treatment device (not shown) on the upstream side in the transport direction. Sequentially from downstream to downstream.

  Explaining the manufacturing process, the long electromagnetic steel sheet 100 is put into the cutting device 6 and cut into a number of tape-shaped soft magnetic strips 2 arranged in a predetermined pitch in the width direction and extending long in the conveying direction. (First step). Each soft magnetic strip portion 2 that has come out of the cutting device 6 is shifted so that two soft magnetic strip portions 2 adjacent to each other are displaced in the plate thickness direction to be larger than the plate thickness. Preferably, all the soft magnetic strip portions 2 are shifted to different positions in the thickness direction.

  Thereafter, each soft magnetic strip portion 2 is transferred to an insulating film processing apparatus, where an insulating film is deposited on at least the cut surface, preferably the entire surface (second step). The insulating film may be deposited by the method described above. Since each soft magnetic strip portion 2 is shifted in the plate thickness direction, it is easy to attach an insulating film to each cut surface. Thereafter, the soft magnetic strip portions 2 are again urged in the direction of canceling the shift in the plate thickness direction, whereby the soft magnetic strip portions 2 are arranged on the same plane. Thereafter, the soft magnetic strip 2 is heated. At this time, the insulating film mechanically couples the two adjacent soft magnetic strip portions 2 (third step). At this time, the soft magnetic strip portion 2 may be annealed. After the heat treatment, a plate-shaped soft magnetic magnetic member 3 to be cooled is formed. Subsequently, the plate-shaped soft magnetic magnetic member 3 is punched out to obtain a soft magnetic magnetic member having a necessary shape.

(Modification)
Note that the cutting device 6 shown in FIG. 4 can have a large number of fine blades facing upstream in the transport direction. If it does in this way, by conveying the electromagnetic steel plate 100 to the conveyance direction downstream, these fine blades can cut the electromagnetic steel plate 1 and can form many soft-magnetic strip parts 2 automatically.

(Modification)
In FIG. 4, a press device (processing device) for punching a necessary shape from the soft magnetic member may be provided on the downstream side of the heat treatment device. In this way, final product shape processing can be performed on a compact production line.

(Modification)
In FIG. 4, a flat soft magnetic member formed by integrating the soft magnetic strips 2 with a heat treatment apparatus is cut into a predetermined length, and then the width direction of the soft magnetic member, that is, the conveying direction is as follows. While feeding in a second transport direction perpendicular to the second transport direction, cuts are sequentially made at a predetermined pitch in the second transport direction in a direction perpendicular to the second transport direction, an insulating film is provided at the cut, and this break is further eliminated. Thus, a soft magnetic member having a dice-like soft magnetic strip portion can be formed by thermocompression bonding.

(Modification)
The above-mentioned many soft magnetic strips 2 are formed only in predetermined portions of the long electromagnetic steel sheet, particularly in regions where reduction of eddy current loss is important, and soft magnetic strips 2 are formed in other portions of the electromagnetic steel plate. You may not form or may form the pitch large.

(Description of various cutting methods)
Various cutting methods that can be employed in cutting the soft magnetic strip portion 2 will be described below.

  The cutting may be performed by a method of separating the soft magnetic strips 2 from the magnetic steel sheet one by one using a cutting device such as a grooving roller, a shearing machine, or a rotating grindstone, or using a cutting die. One-way cutting work or the two-way cutting work may be performed at once. In addition, you may cut | disconnect using beams, such as a water jet and a laser beam. Cutting using such a beam is suitable for forming a large number of soft magnetic strip portions 2 only in a partial region of the electromagnetic steel sheet.

  Some examples of the cutting method described above are shown in FIGS. FIG. 5 shows an example of die cutting. The electromagnetic steel sheet 100 is cut at a high speed by the mold 101 and is cut into pieces at once. FIG. 6 shows an example in which the electromagnetic steel sheet 100 is cut by pushing it between a pair of disk-shaped slitters 102 that rotate. High speed cutting is possible. FIG. 7 shows an example of cutting by the carbon dioxide laser 103, for example. The degree of freedom of the cutting shape is improved. FIG. 8 shows an example of cutting with a water jet. Thermal adverse effects can be prevented. In addition, you may cut | disconnect by a wire cut method.

(Modification)
In manufacturing the above-described soft magnetic member, the long magnetic steel sheet 100 is completely separated from each other in each of the soft magnetic strips 2 after the cutting device. Some may be connected to each other. In this way, handling becomes easy. Further, it is preferable that the portion connecting the soft magnetic strip portions 2 is disposed in a portion where the eddy current loss does not cause a problem in the magnetic circuit formed by the soft magnetic member 3.

(Embodiment 4)
A soft magnetic magnetic member and a manufacturing method thereof according to Embodiment 4 will be described below with reference to FIG. FIG. 9 is a schematic plan view of this soft magnetic magnetic member.

  In this embodiment, one or more long soft magnetic wires 7 are used in place of a large number of soft magnetic strip portions formed by cutting the magnetic steel sheet described above. FIG. 9 shows an example using a single soft magnetic wire in which an insulating film is previously deposited on the outer peripheral surface thereof. The soft magnetic wire 7 is spirally wound so as to finally become a rectangular plate, and then heat-treated to integrate the turns of the soft magnetic wire 7.

  The soft magnetic wire 7 is preferably wound around the gap between the two disks extending in the radial direction with a gap slightly larger than the diameter of the soft magnetic wire 7 separated in the axial direction. . If the core is square, a flat soft magnetic magnetic member having a square hole can be formed, and if the core is cylindrical, a ring-shaped soft magnetic magnetic member having a circular hole can be formed. it can. Of course, a plurality of soft magnetic wires 7 may be wound simultaneously instead of one soft magnetic wire 7.

(Modification)
In the above embodiment, the soft magnetic wire 7 is wound in a spiral shape, but may be wound in a coil shape in the axial direction. In this way, a cylindrical or prismatic soft magnetic magnetic member can be formed.

(Embodiment 5)
A soft magnetic magnetic member and a manufacturing method thereof according to Embodiment 5 will be described below with reference to FIGS. FIG. 10 is a schematic process diagram showing a part of the manufacturing process of the soft magnetic magnetic member, and FIG. 11 is a schematic perspective view of the manufactured flat soft magnetic wire.

  In this embodiment, a large number of rolls 80 each having a single soft magnetic wire 7 with an insulating film previously deposited thereon are arranged at a predetermined pitch in the width direction. In this embodiment, the axis of each roll 80 is in the vertical direction. The respective soft magnetic wires 7 drawn from the respective rolls 80 are guided by guide rollers (not shown) so as to approach each other, and finally the gap between the respective soft magnetic wires 7 is substantially zero. The cross section of the soft magnetic wire 7 is preferably square, but may be other cross sectional shapes such as a round shape for various reasons.

  The rows of the soft magnetic wires 7 with almost zero gaps are cut, or after being heated to a predetermined temperature and then cooled, the insulating films of the soft magnetic wires 7 are integrated with each other. As a result, each soft magnetic thin wire 7 becomes a flat soft magnetic member 3 as shown in FIG.

(Embodiment 6)
A soft magnetic magnetic member and a manufacturing method thereof according to Embodiment 6 will be described below with reference to FIG. FIG. 12 is a schematic process diagram showing the manufacturing process of this soft magnetic magnetic member.

  In this embodiment, a soft magnetic magnetic member 8 such as an electromagnetic steel plate, to which an insulating film is applied in advance, is laminated to form a block-like laminated electromagnetic steel plate 9 (a). Next, this laminated electromagnetic steel sheet (a laminated body of soft magnetic magnetic members) 8 is cut in the laminating direction (b), and soft magnetic magnetic members (more precisely, a laminated body of soft magnetic magnetic members) 3 are formed one by one. To do. A cutting tool 10 as shown in FIG. 7 is used as a cutting tool, but cutting may be performed using a milling machine. The formed soft magnetic magnetic member 3 has a large number of soft magnetic strips having a predetermined width in the direction perpendicular to the stacking direction of the laminated electromagnetic steel sheets 9, and this predetermined width is the thickness of the soft magnetic magnetic member 3. That is, a large number of soft magnetic strip portions each constituting a soft magnetic magnetic member 3 cut into a narrow width constitute a soft magnetic magnetic member (more precisely, a laminated body of soft magnetic magnetic members) 3.

  According to this embodiment, for example, an insulating film of a purchased electrical steel sheet can be used as the insulating film between the soft magnetic strip portions 2. In addition, instead of the electromagnetic steel plate, an insulating film may be applied to the surface of the mild steel plate to substitute the electromagnetic steel plate, or an insulating film may be applied to the surface of the amorphous alloy sheet to replace the electromagnetic steel plate.

(Embodiment 7)
A laminate formed by laminating the above-described flat soft magnetic magnetic member 3 in the thickness direction and a manufacturing method thereof will be described.

  It is the same as a conventional laminated electrical steel sheet that a laminated body of soft magnetic members can be manufactured by laminating the flat soft magnetic members 3 described above. In this case, since the insulating film can be applied to the main surface of the flat soft magnetic magnetic member 3 by the above-described insulating film applying process, for example, a soft steel sheet can be used instead of the electromagnetic steel sheet. Moreover, even if the soft magnetic magnetic member 3 is formed using an electromagnetic steel plate having an insulating film previously deposited on the main surface, the main surface of the soft magnetic magnetic member 3 has an insulating film.

(Embodiment 8)
Another structure of the laminated body of soft magnetic members will be described with reference to FIG. FIG. 13A is an exploded perspective view showing an example in which two soft magnetic magnetic members are laminated, and FIG. 13B is an exploded perspective view showing an example in which four soft magnetic magnetic members are laminated.

  In FIG. 13A, when the flat soft magnetic members 3 are laminated, the soft magnetic strip portions 2 of the soft magnetic members 3A and 3B adjacent to each other are laminated in different directions. In this way, since the magnetic flux component in the extending direction A mainly passes through the soft magnetic member 3A when the magnetic flux density is low, the magnetic resistance can be reduced. Similarly, since the magnetic flux component in the extending direction B mainly passes through the soft magnetic member 3B when the magnetic flux density is low, the magnetic resistance can be reduced.

  Of course, the extending direction of the soft magnetic strip portions 2 of the two soft magnetic magnetic members 3A and 3B adjacent to each other can have a predetermined angle instead of a right angle. The extending directions of the soft magnetic strips 2 may be different. Further, the flat soft magnetic member can be formed in a desired shape instead of the square as shown in FIG. Furthermore, as shown in FIG. 13 (b), the extending directions of the soft magnetic strip portions 2 of the plurality of soft magnetic members adjacent to each other or separated in the stacking direction may be made to coincide. In short, the extending direction of the soft magnetic strip portion of each soft magnetic member of the laminate is free. By constructing a laminated body using the soft magnetic magnetic members 3 in which the extending directions of the soft magnetic strip portions 2 are different, both the magnetic characteristics and the strength can be improved.

(Embodiment 9)
Another structure of the laminated body of soft magnetic members will be described with reference to FIG.

  In this embodiment, when forming the laminated body 30 by laminating the flat soft magnetic magnetic members 3, the shape of each soft magnetic magnetic member 3 in the direction perpendicular to the plate thickness direction (plane direction) is the three-dimensional shape of the final product. The feature is that it has been changed to match. In this way, while all the electromagnetic steel sheets have the same surface shape as in the conventional laminated electromagnetic steel sheet, a complicated three-dimensional magnetic member can be composed of a laminate of soft magnetic magnetic members. it can.

  To explain further, the flat-plate-shaped soft magnetic magnetic member 3 formed by a large number of the soft-magnetic strips described above has a relatively small eddy current loss even when a magnetic flux passes in the plate thickness direction. Thus, it is possible to realize a complicated three-dimensional magnetic member while suppressing eddy current loss by laminating soft magnetic magnetic members 3 having different surface shapes.

(Modification)
In the case of constituting a three-dimensional magnetic member, a part of the magnetic member may be constituted by a magnetic member other than the above-described laminated body of soft magnetic magnetic members, for example, a magnetic member made of an amorphous alloy or a normal laminated electrical steel sheet. .

(Embodiment 10)
Another structure of the soft magnetic member will be described with reference to FIG. FIG. 15A is a schematic diagram showing the main part of the manufacturing process, FIG. 15B is an example cross-sectional view of the soft magnetic magnetic member 11, and FIG. 15C is a bundle of soft magnetic magnetic members 11 formed. It is other example sectional drawing.

  In this embodiment, after bundling a large number of soft magnetic wires 7 to which an insulating film is applied in advance, a heat treatment is performed to bond the soft magnetic wires 7 to form a rope-like soft magnetic magnetic member 11. The rope-shaped soft magnetic magnetic member 11 is further wound or arranged to form a laminated body of magnetic members having a desired shape. In this way, a laminate of soft magnetic magnetic members can be constructed with high productivity. The cross section of the rope-shaped soft magnetic magnetic member 11 may be circular as shown in FIG. 15B, square as shown in FIG. 15C, or any other shape such as a cylindrical cross section. It can be a cross section. The laminated body of soft magnetic members is preferably further wound to form a cylindrical magnetic member or a disk-like magnetic member. Moreover, the target magnetic member can also be comprised by arrange | positioning several rope-shaped soft-magnetic magnetic members 11 in a different direction. For example, a plurality of rope-shaped soft magnetic magnetic members 11 may be knitted, woven, or arranged.

(Embodiment 11)
The soft magnetic magnetic member of Embodiment 11 will be described with reference to FIG. FIG. 16 is a partial front view showing a part of the stator core (for one magnetic pole).

  In this embodiment, the soft magnetic magnetic member 3 is composed of a single electromagnetic steel plate formed in a ring shape so as to constitute a stator core of a motor, and each soft magnetic magnetic member 3 is laminated in the axial direction as in the prior art. Thus, a stator core is formed.

  In this embodiment, as shown in FIG. 16, a number of slits (slits) 12 and 13 are provided at a predetermined portion at the same time when a single electromagnetic steel sheet is punched into the shape of a substantially annular plate-shaped stator core. The substantially ring-shaped soft magnetic magnetic member 3 has teeth (which may be considered magnetic pole portions) 14 and an annular yoke 15 protruding in the centripetal direction.

  A large number of slits 12 are cut into the teeth 14 in parallel with the extending direction of the teeth 14, and a large number of slits 13 are cut into the annular portion of the yoke 15 where the teeth 14 do not exist in the circumferential direction.

  As a result, a large number of soft magnetic strips 16 are formed on the teeth 14 of the soft magnetic magnetic member 3 having a substantially annular plate shape, and a large number of soft magnetic strips 17 are formed on the soft magnetic magnetic member 3 having a substantially annular plate shape. The yoke 15 is formed at a portion other than the teeth.

  An insulating film is formed on the cuts (slits) separating the soft magnetic strips 16 and 17 by the method described above, and the adjacent soft magnetic strips 16 and 17 are joined together to improve the rigidity of the stator core. In addition, the electrical insulation performance between them is improved.

  Since the extending direction of the soft magnetic strip portions 16 and 17 substantially coincides with the magnetic flux direction, the increase in the magnetic resistance of the stator core can be minimized while reducing the eddy current loss.

  Each of the slits 12 and 13 may be cut after punching out the substantially ring-shaped soft magnetic magnetic member 3 from a flat electromagnetic steel plate. In this case, the slits may be formed sequentially or divided into a plurality of times. Good. In forming the slit, the cutting tool may be moved, or the soft magnetic member 3 may be moved linearly or rotationally. However, the heat treatment is preferably performed lastly after the slits 12 and 13 are cut.

  Moreover, it is preferable that the positions of the slits 12 provided in the two substantially circular plate-shaped soft magnetic magnetic members 3 adjacent to each other in the stacking direction are different from each other in the circumferential direction. It is preferable to be different.

Embodiment 12
The laminated body of the soft magnetic magnetic member of Embodiment 12 and its manufacturing method are demonstrated below with reference to FIG. FIG. 17 shows a cylindrical laminated body 18 formed by winding the soft magnetic thin wire 7, and this cylindrical laminated body 18 can be used as, for example, a back yoke or a toroidal core of a rotating electric machine.

  The cylindrical laminated body 18 is formed by winding one or more soft magnetic wires 7 previously coated with an insulating film in the radial direction and the axial direction many times. The cross section of the soft magnetic wire 7 is preferably square, but may be other cross sectional shapes such as a round shape for various reasons. Although it is assumed that the magnetic flux flows mainly in the circumferential direction, the magnetic flux may flow in the radial direction or other directions. In this way, the eddy current loss can be remarkably reduced by the conventional laminated electromagnetic steel sheet as compared with the same shape.

  In FIG. 17, the soft magnetic thin wire 7 is wound to form the cylindrical laminated body 18 as a laminated body of soft magnetic magnetic members. However, the rope-like soft magnetic magnetic member previously bundled is wound to obtain the same structure. Of course, the shape can be configured.

(Embodiment 13)
A soft magnetic magnetic member and a manufacturing method thereof according to Embodiment 13 will be described below with reference to FIG. FIG. 18 is a partial front view showing a part (one magnetic pole part) of a stator core made of laminated electromagnetic steel sheets.

  In this embodiment, the soft magnetic magnetic member 3 is formed in a substantially annular plate shape to constitute a stator core of a motor, and a stator core is formed by laminating a plurality of substantially magnetic plate-shaped soft magnetic magnetic members 3 in the axial direction. Has been.

  In this embodiment, as shown in FIG. 18, the soft magnetic magnetic member 3 has a substantially annular plate shape as a whole on a plane extending in the radial direction with a large number of soft magnetic thin wires 7 to which an insulating film is applied in advance. The soft magnetic magnetic members 3 are arranged so as to be formed, and then thermocompression-bonded to form the substantially magnetic plate-shaped soft magnetic magnetic members 3.

  The important point is that each soft magnetic wire 7 is curved or bent with a necessary curvature at a necessary portion in a radially extending plane. The soft magnetic wire 7 has a square cross section with a side of 0.5 mm, for example, and is extremely thin and can be flexibly bent.

  As shown in FIG. 18, among the portions of the back yoke (yoke) 15 of the stator core, the soft magnetic fine wires 7 extending radially inward in the circumferential direction are teeth of the stator core (which may be considered as magnetic pole portions) 14. It is arrange | positioned in the circumferential direction outer side, and has reached the radial direction inner end of the teeth 14. FIG.

  Further, among the portions of the back yoke 15 of the stator core, the soft magnetic fine wire 7 extending radially outward in the circumferential direction is disposed at the center in the circumferential direction of the teeth (which may be considered as magnetic pole portions) 14 of the stator core. The tooth 14 reaches the inner end in the radial direction.

  Further, among the portions of the back yoke 15 of the stator core, the soft magnetic fine wires 7 extending in the circumferential direction on the radially outermost side do not enter the teeth (which may be considered as magnetic pole portions) 14 of the stator core, and thus in the circumferential direction. It extends to.

  In this way, the eddy current loss can be significantly reduced compared to the conventional stator core laminated with a substantially ring-shaped electromagnetic steel sheet, and the eddy current loss characteristics comparable to the dust core can be achieved. Efficiency improvement can be realized at low cost. In addition, when the technical ideas of the above-described embodiments are applied to a stationary device (for example, a transformer on a pillar), the core is much lower in cost than the dust core and much lower in loss than the laminated electrical steel sheet. Can be realized, and energy saving effect can be widely brought to the industry.

FIG. 3 is a schematic manufacturing process diagram of the soft magnetic magnetic member showing the first embodiment. (A)-(f) is a schematic plan view of the soft-magnetic member which shows the arrangement | sequence system of the soft-magnetic strip part of FIG. 1, respectively. 6 is a schematic perspective view of a soft magnetic magnetic member showing Embodiment 2. FIG. FIG. 6 is a schematic manufacturing process diagram of a soft magnetic magnetic member showing Embodiment 3. It is a model perspective view which shows the example of a cutting | disconnection by the metal mold | die for soft-magnetic strip part manufacture. It is a model perspective view which shows the example of a cutting | disconnection by the slitter for soft-magnetic strip part manufacture. It is a model perspective view which shows the example of a cutting | disconnection by the laser for soft-magnetic strip part manufacture. It is a model perspective view which shows the example of a cutting | disconnection by the water jet for soft-magnetic strip part manufacture. 6 is a schematic plan view of a soft magnetic magnetic member showing Embodiment 4. FIG. FIG. 10 is a schematic process diagram illustrating a part of the manufacturing process of the soft magnetic magnetic member according to the fifth embodiment. 10 is a schematic perspective view of a soft magnetic wire according to Embodiment 5. FIG. FIG. 10 is a schematic process diagram showing a soft magnetic magnetic member manufacturing process of Embodiment 6. It is explanatory drawing which shows the laminated body of the soft-magnetic magnetic member of Embodiment 8, (a) is the exploded perspective view which laminated | stacked two sheets, (b) is the exploded perspective view which laminated | stacked four sheets. FIG. 10 is an explanatory view showing a laminated body of soft magnetic magnetic members according to Embodiment 9. FIGS. 15A and 15B are schematic views showing a main part of the manufacturing process, FIG. 15B is an example cross-sectional view of the soft magnetic member 11, and FIG. 15C is bundled. It is other example sectional drawing of the soft-magnetic magnetic member 11 formed in this way. It is a partial front view which shows the soft-magnetic magnetic member of Embodiment 11. FIG. 16 is an explanatory view showing a laminated body of soft magnetic magnetic members of Embodiment 12. It is explanatory drawing which shows the soft-magnetic magnetic member of Embodiment 13.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Thin plate 2 Soft-magnetic strip part 3 Soft-magnetic member 3A Soft-magnetic member 3B Soft-magnetic member 4, 5 Cutting direction 6 Cutting device 7 Soft-magnetic thin wire 8 Soft-magnetic member 9 Laminated electrical steel sheet 10 Byte 11 Soft-magnetic magnet Member 12 Slit 13 Slit 14 Teeth 15 Back yoke (yoke)
16 Soft magnetic strip portion 17 Soft magnetic strip portion 18 Cylindrical laminated body 30 Laminated body 80 Roll 100 Electrical steel sheet

Claims (12)

In a soft magnetic magnetic member formed in a plate shape using a soft magnetic metal material as a raw material,
In together when made of a soft magnetic metallic material to a thickness direction perpendicular to the first arrangement direction are arranged at a predetermined pitch,
And a large number of soft magnetic strip portions arranged at a predetermined pitch in a second arrangement direction perpendicular to the plate thickness direction ,
An inorganic insulating film that is deposited or formed on the surface of the soft magnetic strip portion to increase the electrical resistance between the soft magnetic strip portions;
Have
The soft magnetic strips are mechanically coupled to each other through the insulating film and formed into a plate shape ,
The insulating film is located between the soft magnetic strip portions adjacent to each other, and is arranged at a predetermined pitch in the first arrangement direction and the second arrangement direction, respectively. Element. The soft magnetic magnetic member according to claim 1 ,
The soft magnetic magnetic member in which the first arrangement direction and the second arrangement direction are orthogonal to each other. A method of manufacturing a soft magnetic magnetic member formed in a plate shape from a soft magnetic metal material,
The soft magnetic magnetic member is made of a soft magnetic metal material and at least a plurality of soft magnetic strip portions arranged at a predetermined pitch in a predetermined arrangement direction perpendicular to the plate thickness direction,
An inorganic insulating film that is deposited or formed on the surface of the soft magnetic strip portion to increase the electrical resistance between the soft magnetic strip portions;
Have
The soft magnetic strips are mechanically coupled to each other via the insulating film and formed into a plate shape, each of which is formed into a long shape and perpendicular to the plate thickness direction and the arrangement direction. Each extending in the direction of extension,
A first step of cutting the magnetic steel sheet into a predetermined width to form the strip-shaped soft magnetic strip portion;
Second step of depositing or forming the insulating film on at least the cut surface of the strip-shaped soft magnetic strip portion
When,
A third step of mechanically coupling a number of the strip-shaped soft magnetic strips to each other through the insulating film
And
Have
The strip-shaped soft magnetic strip portion formed by cutting the electromagnetic steel sheet to a predetermined width is displaced by a predetermined distance relative to the adjacent strip-shaped soft magnetic strip portion in the plate thickness direction. A method of manufacturing a soft magnetic member in which the displacement is eliminated after the insulating film is deposited or formed, and then the mechanical coupling is performed. A method of manufacturing a soft magnetic magnetic member formed in a plate shape from a soft magnetic metal material,
The soft magnetic magnetic member is made of a soft magnetic metal material and at least a plurality of soft magnetic strip portions arranged at a predetermined pitch in a predetermined arrangement direction perpendicular to the plate thickness direction,
An inorganic insulating film that is deposited or formed on the surface of the soft magnetic strip portion to increase the electrical resistance between the soft magnetic strip portions;
Have
The soft magnetic strips are mechanically coupled to each other via the insulating film and formed into a plate shape, each of which is formed into a long shape and perpendicular to the plate thickness direction and the arrangement direction. Each extending in the direction of extension,
Along with conveying a long electromagnetic steel sheet in a predetermined conveying direction, at the upstream part in the conveying direction, performing a first step of cutting the electromagnetic steel sheet into a predetermined width to form a strip-shaped soft magnetic strip part,
Performing a second step of depositing or forming the insulating film on at least the cut surface of the strip-shaped soft magnetic strip portion at the midstream portion in the transport direction;
In the method of manufacturing a soft magnetic member that performs a third step of mechanically coupling a number of the strip-shaped soft magnetic strip portions to each other via the insulating film at a downstream portion in the transport direction,
The manufacturing method of the soft-magnetic magnetic member which forms the said soft-magnetic strip part in strip | belt shape by tearing the said electromagnetic steel plate to the said conveyance direction as the said long electromagnetic steel plate moves to the said conveyance direction. In laminates made of soft magnetic metal materials,
A large number of soft magnetic strips made of a soft magnetic metal material and arranged at a predetermined pitch in a predetermined arrangement direction at least perpendicular to the plate thickness direction;
An inorganic insulating film that is deposited or formed on the surface of the soft magnetic strip portion to increase the electrical resistance between the soft magnetic strip portions;
Have
A laminated body of soft magnetic magnetic members in which a plurality of soft magnetic magnetic members, in which the soft magnetic strip portions are mechanically coupled to each other via the insulating film and formed into a plate shape, are laminated in the plate thickness direction. . The laminate of soft magnetic magnetic members according to claim 5 ,
A laminated body of soft magnetic magnetic members in which the insulating films of the two laminated plate-like soft magnetic magnetic members extend in different directions. The laminate of soft magnetic magnetic members according to claim 6 ,
A laminated body of soft magnetic magnetic members in which an extending direction of at least one of the two plate-like soft magnetic magnetic members is set to a substantially magnetic flux passing direction. The laminate of soft magnetic magnetic members according to claim 6 ,
A laminate of the soft magnetic magnetic members in which the extending directions of the insulating films of the two plate-like soft magnetic magnetic members are orthogonal to each other. 6. The laminated body of soft magnetic magnetic members according to claim 5, wherein a magnetic circuit is constituted by being combined with a soft magnetic magnetic member other than the laminated body of soft magnetic members. In the manufacturing method of the laminated body of the soft-magnetic magnetic member of Claim 5 ,
A first step of cutting a laminated body of soft magnetic members into a predetermined width to form a laminated body of the strip-shaped soft magnetic strip portions;
A second step of depositing or forming the insulating film on at least a cut surface of the laminate of the strip-shaped soft magnetic strip portion;
A third step of forming a laminate of the soft magnetic magnetic members by mechanically coupling a plurality of laminates of the strip-shaped soft magnetic strip portions with each other through the insulating film;
A method of manufacturing a laminate of soft magnetic magnetic members having In the manufacturing method of the laminated body of the soft-magnetic magnetic member of Claim 10 ,
A method for producing a laminate of soft magnetic magnetic members, wherein the cut surface of the laminate of soft magnetic magnetic members is formed in a direction perpendicular to the lamination direction. In the manufacturing method of the laminated body of the soft-magnetic magnetic member of Claim 6 ,
A number of the soft magnetic members are sequentially cut into a predetermined planar shape,
A method of manufacturing a laminated body of soft magnetic magnetic members, wherein the cut soft magnetic magnetic members are sequentially laminated to form a laminated body of soft magnetic magnetic members having a predetermined three-dimensional shape.

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