WOUND CORE

Abstract

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 μm.sup.2. 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.

Claims

1. A wound core comprising a flat portion and corner portions adjacent to the flat portion, the flat portion including a lap portion, the corner portions including bent portions, wherein: in the wound core, a non-heat-resistant magnetic domain refined material is used for at least a part of 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 μm.sup.2; and 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.

2. The wound core according to claim 1, wherein the closure domains have a depth of 60 μm or more.

3. The wound core according to claim 1, wherein the closure domains in the non-heat-resistant magnetic domain refined material are formed with a spacing of more than 3.0 mm and less than 8.0 mm in the longitudinal direction.

4. The wound core according to claim 2, wherein the closure domains in the non-heat-resistant magnetic domain refined material are formed with a spacing of more than 3.0 mm and less than 8.0 mm in the longitudinal direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 A graph showing the relation between a building factor (B.F.) and the area of a closure domain in a cross section that is taken in the longitudinal direction (the cross-sectional area of the closure domain).

[0034] FIG. 2 A graph showing the relation between the building factor (B.F.) and a lap length in wound cores.

[0035] FIG. 3 A graph showing the results of examination of the relation between the building factor (B.F.) and the cross-sectional area of each closure domain, the examination being performed with one of the width of the closure domain and the depth of the closure domain changed variously.

[0036] FIG. 4 A graph showing the relation between core material iron loss and a line spacing.

[0037] FIG. 5 A schematic illustration (side view) showing the structure of a wound core.

[0038] FIG. 6 Schematic illustrations showing joining methods (step lap joining and overlap joining) in wound cores.

[0039] FIG. 7 A schematic illustration illustrating the definitions for closure domains.

[0040] FIG. 8 Schematic illustrations showing examples of a wound core in which a non-heat-resistant magnetic domain refined material is used at least for a part thereof.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0041] The structure of the wound core according to aspects of the present invention will be specifically described.

<Wound Core>

[0042] The wound core has bent portions in corner portions and a lap portion in a flat portion and is of the type that requires no strain relief annealing. For example, the wound core is effective for a unicore type wound core and a duocore type wound core. In a Tranco core type wound core that requires strain relief annealing, the closure domains, which are the feature of aspects of the present invention, are annihilated by the strain relief annealing, and the effects according to aspects of the present invention are not obtained. FIG. 5 schematically illustrates a side view of the wound core. Straight lines are drawn to perpendicular directions of stacking so as to pass through end points of bending of the innermost steel sheet. These straight lines are used as boundaries between corner portions and flat portions. As shown in FIG. 5, the wound core according to aspects of the present invention includes the flat portions and the corner portions adjacent to the flat portions. In the wound core, the flat portions and the corner portions are arranged alternately in a continuous manner. The wound core has a substantially rectangular shape in a side view. The wound core according to aspects of the present invention has a lap portion in a flat portion and bent portions in the corner portions. When the wound core is of the unicore type, one of the four flat portions has a lap portion. When the wound core is of the duocore type, two of the four flat portions have respective lap portions. Each lap portion has joint portions (lap joint portions) that are formed by stacking steel sheets formed of a core material in their thickness direction so as to overlap each other by a lap length.

[0043] Generally, an overlap-type joining method (overlap joining) or a step lap-type joining method (step lap joining) shown in FIG. 6 is used. The effects according to aspects of the present invention can be obtained with any of these methods. However, the effects obtained by applying aspects of the present invention are higher when the number of occurrences of interlaminar magnetic flux transfer in a direction perpendicular to the sheet surface is larger. In the overlap type and the step lap type shown in FIG. 6, the number of occurrences of interlaminar magnetic flux transfer is larger in the step lap type, and therefore the effects according to aspects of the present invention are higher when aspects of the invention is applied to the step lap type core. In a unicore, one lap joint portion is present in one turn. In a duocore, two lap joint portions are present in one turn. Therefore, the effects according to aspects of the invention can be more effectively utilized when aspects of the invention is applied to the duocore.

[0044] In a wound core, if the lap length in lap joint portions (see FIG. 6) is less than 3.0 mm, iron loss deterioration due to magnetic flux concentration is large, and the effects according to aspects of the invention are not obtained sufficiently. If the lap length is more than 30 mm, the influence of the increase in magnetic flux density waveform distortion due to the increase in the area of non-uniform magnetic flux regions is large, and the effects according to aspects of the invention are also not obtained sufficiently. Therefore, the lap length range in which the effects according to aspects of the invention can be utilized is from 3.0 mm to 30 mm. Generally, in one wound core, the lap lengths are constant or substantially constant. However, aspects of the present invention are effective for a wound core in which the lap lengths are not constant. Even in this case, the effects according to aspects of the invention can be utilized when the ratio of the number of lap joint portions with a lap length of from 3.0 mm to 30 mm to the total number of lap joint portions [(the number of lap joint portions with a lap length of from 3.0 mm to 30 mm/the total number of lap joint portions)×100] is 50% or more. The above ratio is preferably 75% or more.

[0045] No particular limitation is imposed on the method for producing the wound core, and, for example, any known method may be used. More specifically, a unicore production apparatus manufactured by AEM is used. In this case, design sizes are inputted into the production apparatus, and steel sheets are sheared and bent into the respective design sizes. The machined steel sheets (raw material sheets) are stacked (stacked in the thickness direction), and the wound core described above can thereby be produced. In accordance with aspects of the present invention, when the wound core is produced, the requirement for the lap portion is controlled so as to fall within the range according to aspects of the present invention. So long as the above requirement is met, no particular limitation is imposed on the other factors such as the size of the core, the bending angles of the bent portions in the corner portions, and the number of bent portions.

[0046] In the wound core according to aspects of the present invention, it is necessary that a prescribed non-heat-resistant (strain-introduced) magnetic domain refined material be used for at least a part of materials forming the wound core. The phrase “the prescribed non-heat-resistant magnetic domain refined material is used for at least a part of materials forming the wound core” means that at least one turn (one layer) of core materials forming the wound core is formed of the prescribed non-heat-resistant magnetic domain refined material. This is because, to utilize the effects according to aspects of the invention, it is necessary to use the prescribed non-heat-resistant magnetic domain refined material in at least one lap joint portion in the wound core.

[0047] In the wound core according to aspects of the present invention, no particular limitation is imposed on the positions of turns (layers) for which the prescribed non-heat-resistant magnetic domain refined material is used. For example, as shown in FIG. 8, one or more turns including the outermost layer of the wound core may be formed of the prescribed non-heat-resistant magnetic domain refined material (FIG. 8(a)). Alternatively, one or more turns including the innermost layer of the wound core may be formed of the prescribed non-heat-resistant magnetic domain refined material (FIG. 8(b)), or one or more turns inside the wound core may be formed of the prescribed non-heat-resistant magnetic domain refined material (FIG. 8(c)). When a plurality of turns are formed of the prescribed non-heat-resistant magnetic domain refined material, the magnetic domain refined material may be used for consecutively stacked layers (FIG. 8(a) to (c)) or may not be used for consecutively stacked layers (FIG. 8(d)). In FIG. 8, grey turns indicate the prescribed non-heat-resistant magnetic domain refined material.

[0048] In the wound core according to aspects of the present invention, the larger the amount of the prescribed non-heat-resistant magnetic domain refined material used, the higher the effects according to aspects of the invention. It is therefore recommended that the ratio of the number of stacked sheets (the number of stacked layers) for which the prescribed non-heat-resistant magnetic domain refined material is used to the total number of stacked sheets (the total number of stacked layers) in the wound core (the wound iron core) be preferably 50% or more and more preferably 75% or more. When the ratio of the number of stacked layers for which the prescribed non-heat-resistant magnetic domain refined material is used is 100% in the wound core produced (i.e., the prescribed non-heat-resistant magnetic domain refined material is used for all the stacked layers of the wound core), the effects according to aspects of the invention obtained can be maximized.

<Non-Heat-Resistant Magnetic Domain Refined Material>

[0049] The non-heat-resistant magnetic domain refined material in accordance with aspects of the present invention is prepared by subjecting the surface of a grain-oriented electrical steel sheet to magnetic domain refining treatment for introducing strain (microstrain) using laser beam, electron beam, or plasma irradiation. No particular limitation is imposed on the grain-oriented electrical steel sheet. For example, any grain-oriented electrical steel sheet obtained by a routine method can be used. The higher the degree of preferred orientation of the grain-oriented electrical steel sheet, the higher the magnetic domain refining effect. Therefore, from the viewpoint of reducing iron loss, the magnetic flux density B.sub.8 is preferably 1.92 T or more.

[0050] Generally, a forsterite coating is formed on the surface of the grain-oriented electrical steel sheet but may not be formed. If necessary, an insulating coating may be formed on the surface of the grain-oriented electrical steel sheet used. The insulating coating means a coating (tension coating) that imparts tension to the steel sheet in order to reduce iron loss. Examples of the tension coating include inorganic-based coatings containing silica and ceramic coatings formed by physical vapor deposition, chemical vapor deposition, etc.

[Magnetic Domain Refining Treatment]

[0051] In accordance with aspects of the present invention, the non-heat-resistant magnetic domain refined material subjected to magnetic domain refining treatment is used for at least a part of the wound core material. No particular limitation is imposed on the magnetic domain refining treatment method. For example, a well-known method using a laser, plasma, an electron beam, etc. may be used. No particular limitation is imposed on the treatment conditions. For example, well-known treatment conditions may be used for the treatment. As for the treatment conditions, the irradiation direction (the extending direction of the closure domains formed by irradiation) is a direction intersecting the rolling direction of the non-heat-resistant magnetic domain refined material (the longitudinal direction, i.e., the RD direction in FIG. 7). The irradiation direction is preferably a direction inclined by 60° to 90° with respect to the rolling direction. The direction inclined by 90° corresponds to a direction orthogonal to the rolling direction (i.e., the TD direction in FIG. 7). Preferably, the output power is 50 W to 5 kW, and the scanning speed is 10 m/sec or more from the viewpoint of productivity.

[0052] One feature of the magnetic domain refining treatment is that the area of each closure domain in a cross section that is taken in the longitudinal direction (the cross-sectional area of each closure domain) is set to more than 7500 μm.sup.2. If the cross-sectional area of each closure domain is smaller than 7500 μm.sup.2, the amount of the closure domains is insufficient, so that the effects according to aspects of the invention such as an increase in optimal lap length and a reduction in loss in the lap portion cannot be obtained. The cross-sectional area of each closure domain is more preferably 10000 μm.sup.2 or more.

[0053] No particular limitation is imposed on the line spacing (the spacing between the closure domains formed). To achieve the most important object, i.e., to reduce the loss in the wound core as much as possible, the line spacing in the non-heat-resistant magnetic domain refined material in the longitudinal direction is preferably more than 3.0 mm and less than 8.0 mm. When the depth of the closure domains is 60 μm or more, the effects according to aspects of the invention can be obtained more easily. No particular limitation is imposed on the method for forming deeper closure domains. It is preferable that the beam diameter is reduced to increase the energy density. From the viewpoint of forming deeper closure domains, the beam diameter is preferably 0.2 mm or less.

EXAMPLES

[0054] Next, aspects of the present invention will be described specifically on the basis of Examples. The following Examples show preferred examples of the invention, and the invention is not limited to these Examples. Embodiments of the invention can be appropriately modified within the range suitable for the gist of the invention, and all the modifications are included in the technical range of the invention.

Example 1

[0055] Grain-oriented electrical steel sheets having the same magnetic flux density (B.sub.8=1.92 T) were prepared and irradiated with a laser or electron beam to perform magnetic domain refining treatment. The irradiation conditions (output power, irradiation line spacing, deflection speed, and beam diameter) are shown in Table 1. Then the iron loss W.sub.17/50 of the material, the cross-sectional area of each closure domain, the depth of the closure domains, and the width of the closure domains were derived.

[0056] The grain-oriented electrical steel sheets subjected to the non-heat-resistant magnetic domain refining treatment were used as core materials to produce wound cores. The weight of each wound core was about 40 kg, and its capacity was 30 kVA. Each wound core was a unicore having a lap portion in one flat portion (one lap joint portion in one turn) and bent portions in corner portions or a duocore having lap portions in two flat portions (two lap joint portions in one turn) and bent portions in corner portions. The lap lengths in each wound core were constant. The unicores and the duocores were each produced by machining the grain-oriented electrical steel sheets such that the bent portions had an angle of 45° and then stacking the resulting sheets. Specifically, wound cores having different lap lengths shown in Table 2 were produced. Then the loss W.sub.17/50 of each of the produced wound cores was measured.

[0057] As shown in Table 1, material A was not subjected to the magnetic domain refining treatment. However, materials B to P were subjected to the magnetic domain refining treatment, and the iron loss in each of these materials was smaller. In materials B, C, F to H, K to M, and P having a line spacing of more than 3.0 mm and less than 8.0 mm, the effect of reducing the material iron loss was higher than that in materials D, I, and N having a line spacing of 3.0 mm or less and that in materials E, J, and O having a line spacing of 8.0 mm or more.

TABLE-US-00001 TABLE 1 Cross- sectional Width of Depth of area of Deflection Beam spacing closure closure each closure Iron loss Power speed diameter Line domains domains domain W.sub.17/50 Material Type (W) (m/sec) (mm) (mm) (μm) (μm) (μm.sup.2) (W/kg) A No magnetic domain refining treatment 0.83 B Laser  100  10 0.12  5 120  40  4800 0.76 C  250  10 0.12  5 120  90 10800 0.73 D  250  10 0.12  2 120  90 10800 0.80 E  250  10 0.12 10 120  90 10800 0.80 F  500  10 0.20  5 200  50 10000 0.76 G Electron  250  40 0.20  7 200  35  7000 0.76 H beam  500  40 0.20  7 200  70 14000 0.75 I  500  40 0.20  1.5 200  70 14000 0.80 J  500  40 0.20  12 200  70 14000 0.80 K  500  40 0.40  7 400  40 16000 0.76 L 1000 100 0.10  6 100  40  4000 0.76 M 2500 100 0.10  6 100 120 12000 0.70 N 2500 100 0.10  0.5 100 120 12000 0.75 O 2500 100 0.10  9 100 120 12000 0.75 P 2500 200 0.10  6 100  40  4000 0.76 Underlines mean outside the range of the invention.

[0058] As shown in Table 2, in wound cores Nos. 1 and 2 produced using only material A not subjected to the magnetic domain refining treatment, loss in the joint portions was very large, and the wound core loss and the building factor were also very large. Comparison between No. 1 and No. 2 shows that the wound core loss and the building factor are larger in the duocore in No. 2. This is because the number of lap joint portions is larger in the duocore. In Nos. 6, 7, 17, 18, 28, and 29, the wound core loss and the building factor are larger than those in the wound cores in the Inventive Examples. This is because the lap length of the lap joint portions is outside the range of the invention. In Nos. 3, 14, and 25 also, the wound core loss and the building factor are large. This is because the cross-sectional area of each of the closure domains formed in the material is outside the range of the invention.

[0059] Nos. 11, 12, 22, 23, 30, and 31 are Inventive Examples. In Nos. 4, 11, and 12, the building factors are the same and good, but the wound core loss is larger in Nos. 11 and 12 than in No. 4. In Nos. 15, 22, and 23, the building factors are the same and good, but the wound core loss is larger in Nos. 22 and 23 than in No. 15. In Nos. 26, 30, and 31, the building factors are the same and good, but the wound core loss is larger in Nos. 30 and 31 than in No. 26. This is because the line spacings in the materials are not optimized. In each of the wound cores in Inventive Examples Nos. 8, 9, 10, 19, 20, and 21, the material outside the range of the invention (material A) was used for a part of the material forming the wound core. In these wound cores, the building factor is higher than those in the Inventive Examples in which all the material forming the wound core is in the range of aspects of the invention. In Nos. 13 and 24, the building factor tends to be slightly higher than those in Nos. 4, 5, 15, 16, 26, and 27 having optimal building factors. In particular, in No. 24, although the volume of the closure domains is sufficient, the building factor tends to be slightly larger than the optimal building factors. This may be because the depth of the closure domains is outside the preferred range. In Nos. 4, 5, 15, 16, 26, and 27 produced under the most preferred conditions, the building factors are most preferred, and the absolute values of the wound core loss are the best.

TABLE-US-00002 TABLE 2 Ratio of lap joint Wound core Lap portions with lap length loss Material Core length of from 3.0 mm to W.sub.17/50 Building No. ratio*.sup.1 type (mm) 30 mm *.sup.2 (%) (W/kg) factor Remarks 1 A 100% Unicore 10 100 1.162 1.40 Comparative Example 2 A 100% Duocore 10 100 1.289 1.55 Comparative Example 3 B 100% Unicore 10 100 1.049 1.38 Comparative Example 4 C 100% Unicore 12 100 0.781 1.07 Inventive Example 5 C 100% Duocore 12 100 0.796 1.09 Inventive Example 6 C 100% Unicore 2.5 0 0.920 1.26 Comparative Example 7 C 100% Unicore 40 0 0.861 1.18 Comparative Example 8 A 80% C Unicore 10 100 0.956 1.18 Inventive Example 20% 9 A 40% C Unicore 10 100 0.878 1.14 Inventive Example 60% 10 A 20% C Unicore 10 100 0.825 1.10 Inventive Example 80% 11 D 100% Unicore 10 100 0.856 1.07 Inventive Example 12 E 100% Unicore 10 100 0.856 1.07 Inventive Example 13 F 100% Unicore 10 100 0.844 1.11 Inventive Example 14 G 100% Unicore 8 100 1.026 1.35 Comparative Example 15 H 100% Unicore 8 100 0.803 1.07 Inventive Example 16 H 100% Duocore 8 100 0.818 1.09 Inventive Example 17 H 100% Unicore 1 0 0.975 1.30 Comparative Example 18 H 100% Unicore 35 0 0.938 1.25 Comparative Example 19 A 80% H Unicore 8 100 0.961 1.18 Inventive Example 20% 20 A 40% H Unicore 8 100 0.923 1.14 Inventive Example 60% 21 A 20% H Unicore 8 100 0.843 1.10 Inventive Example 80% 22 100% Unicore 8 100 0.856 1.07 Inventive Example 23 J 100% Unicore 8 100 0.856 1.07 Inventive Example 24 K 100% Unicore 8 100 0.851 1.12 Inventive Example 25 L 100% Duocore 16 100 1.120 1.48 Comparative Example 26 M 100% Duocore 16 100 0.763 1.09 Inventive Example 27 M 100% Unicore 16 100 0.749 1.07 Inventive Example 28 M 100% Duocore 0.5 0 0.987 1.41 Comparative Example 29 M 100% Duocore 50 0 0.931 1.33 Comparative Example 30 N 100% Duocore 16 100 0.818 1.09 Inventive Example 31 O 100% Duocore 16 100 0.818 1.09 Inventive Example 32 P 100% Duocore 16 100 1.071 1.41 Comparative Example *.sup.1The ratio of the number of stacked material sheets to the total number of stacked sheets in the wound core. *.sup.2 (The number of lap joint portions with a lap length of from 3.0 mm to 30 mm/the total number of lap joint portions) × 100 Underlines mean outside the range of the invention.

Example 2

[0060] Unicores having the same shape as that in Example 1 except for the lap lengths were produced using materials A, C, H, and M in Example 1. Unlike in Example 1, in Example 2, different lap lengths in value ranges in “Lap lengths changed for different layers” shown in Table 3 were used for different turns (different layers). In some wound cores (in which the value indicated in “Lap lengths changed for different layers” shown in Table 3 is constant), the lap length was set to be constant (fixed) The ratio of the number of lap joint portions with a lap length of from 3.0 mm to 30 mm (the ratio of the number of lap joint portions with a lap length of from 3.0 mm to 30 mm to the total number of lap joint portions), which is important in accordance with aspects of the present invention, is shown in Table 3. As can be seen from the results in Table 3, when material A not subjected to the magnetic domain refining treatment was used, the building factor was very high, irrespective of the ratio of the number of lap joint portions with a lap length of from 3.0 mm to 30 mm. However, when materials C, H, and M subjected to the prescribed magnetic domain refining treatment were used, the building factor was good when the ratio of the number of lap joint portions with a lap length of from 3.0 mm to 30 mm was in the range according to aspects of the invention.

TABLE-US-00003 TABLE 3 Lap lengths Ratio of lap joint Wound changed portions with lap core for different length of from loss Material layers*.sup.2 3.0 mm to 30 W.sub.17/50 Building No. ratio*.sup.1 Core type (mm) mm*.sup.3 (%) (W/kg) factor Remarks 41 A 100% Unicore  10 100 1.166 1.40 Comparative Example 42 A 100% Unicore   1~40 80 1.166 1.40 Comparative Example 43 A 100% Unicore   1~40 60 1.168 1.41 Comparative Example 44 A 100% Unicore   1~40 30 1.170 1.41 Comparative Example 45 A 100% Unicore   1~40 10 1.172 1.41 Comparative Example 46 C 100% Unicore   4 100 0.788 1.08 Inventive Example 47 C 100% Unicore 0.5~5 80 0.792 1.08 Inventive Example 48 C 100% Unicore 0.5~5 50 0.802 1.10 Inventive Example 49 C 100% Unicore 0.5~5 30 0.886 1.21 Comparative Example 50 C 100% Unicore 0.5~5 10 0.931 1.24 Comparative Example 51 H 100% Unicore  25 100 0.821 1.09 Inventive Example 52 H 100% Unicore  20~40 80 0.825 1.10 Inventive Example 53 H 100% Unicore  20~40 60 0.830 1.11 Inventive Example 54 H 100% Unicore  20~40 30 0.901 1.20 Comparative Example 55 H 100% Unicore  20~40 10 0.920 1.23 Comparative Example 56 M 100% Unicore  10 100 0.763 1.09 Inventive Example 57 M 100% Unicore   1~40 75 0.768 1.10 Inventive Example 58 M 100% Unicore   1~40 50 0.779 1.11 Inventive Example 59 M 100% Unicore   1~40 30 0.850 1.21 Comparative Example 60 M 100% Unicore   1~40 10 0.880 1.26 Comparative Example *.sup.1The ratio of the number of stacked material sheets to the total number of stacked sheets in the wound core. *.sup.2Each value range means that the lap lengths for different layers were changed within the range. *.sup.3(The number of lap joint portions with a lap length of from 3.0 mm to 30 mm/the total number of lap joint portions) × 100 Underlines mean outside the range of the invention.