阅读说明：本技术 Fe基软磁性非晶合金薄板及制法、层叠铁芯和旋转电机 (Fe-based soft magnetic amorphous alloy sheet, method for producing the same, laminated iron core, and rotating electrical machine ) 是由 井上政己 高岛洋 森次仲男 于 2021-03-25 设计创作，主要内容包括：本发明提供能够容易地降低层叠铁芯的损耗的Fe基软磁性非晶合金薄板、使用该薄板的层叠铁芯和旋转电机、以及Fe基软磁性非晶合金薄板的制造方法。本发明的层叠铁芯用的Fe基软磁性非晶合金薄板的特征在于,所述薄板具有：相对的正面背面；和侧面,所述薄板的厚度为10～50μm,所述侧面具有从正面背面侧起分别相对于所述薄板的厚度方向倾斜的断裂面,所述侧面在所述薄板的厚度方向的截面上为向端部去逐渐变细的V字形状。(The invention provides an Fe-based soft magnetic amorphous alloy sheet, a laminated core and a rotating electrical machine using the same, and a method for manufacturing the Fe-based soft magnetic amorphous alloy sheet, wherein the loss of the laminated core can be easily reduced. The Fe-based soft magnetic amorphous alloy sheet for a laminated core according to the present invention is characterized by comprising: an opposite front and back face; and side surfaces, the thickness of the sheet is 10 to 50 μm, the side surfaces have fracture surfaces inclined from the front surface and the back surface relative to the thickness direction of the sheet, and the side surfaces are in a V shape tapering toward the end in the thickness direction of the sheet.)

1. A Fe-based soft magnetic amorphous alloy sheet for a laminated iron core, characterized in that:

the sheet has: an opposite front and back face; and a side surface, the thickness of the thin plate is 10-50 μm,

the side surface has a fracture surface inclined from the front surface side to the back surface side with respect to the thickness direction of the sheet, and the side surface has a V-shape tapered toward the end in the thickness direction of the sheet.

2. The Fe-based soft magnetic amorphous alloy sheet according to claim 1, characterized in that:

the fracture surface is a fracture surface generated by ductile fracture.

3. A Fe-based soft magnetic amorphous alloy sheet according to claim 1 or 2, characterized in that:

all the side surfaces of the thin plate are V-shaped.

4. A Fe-based soft magnetic amorphous alloy sheet according to any one of claims 1 to 3, characterized in that:

a region of a distance of 5 μm or more from the V-shaped end portion as the outer edge of the thin plate toward the inside is a fracture surface.

5. A laminated core, characterized in that:

the Fe-based soft magnetic amorphous alloy sheet according to any one of claims 1 to 4, which is formed by stacking.

6. A rotating electric machine characterized by:

the laminated core according to claim 5 is used in a stator or a rotor.

7. A method for producing an Fe-based soft magnetic amorphous alloy sheet according to any one of claims 1 to 3, comprising:

a step of superposing a thin strip of Fe-based soft magnetic amorphous alloy and a thin strip of a non-metal having a thickness of 10 to 150 μm, and

and cutting the thin strip of the Fe-based soft magnetic amorphous alloy and the non-metal thin strip by using a rotary die cutter or a Thomson knife.

Technical Field

The present invention relates to an Fe-based soft magnetic amorphous alloy thin plate, a laminated iron core and a rotating electrical machine using the same, and a method for manufacturing the Fe-based soft magnetic amorphous alloy thin plate.

Background

In order to ensure output, rotating electric machines used as electric motors for electric vehicles and hybrid electric vehicles are required to operate at high efficiency by reducing loss due to high frequency of alternating magnetic flux caused by high-speed rotation. Up to now, the efficiency of the rotating electric machine has been improved by using an inverter, applying a rare earth magnet, optimizing a structural design, and the like, but in order to further improve the efficiency, it is necessary to reduce the iron loss of the laminated iron core used for the magnetic pole. Therefore, there is an increasing demand for low-loss magnetic materials such as Fe-based soft magnetic amorphous alloys, Fe-based nanocrystalline soft magnetic alloys containing a fine bcc structure, an Fe crystal phase containing an FeSi crystal phase and an amorphous phase, and the like, to be used in place of the electromagnetic steel sheets conventionally used for laminated cores.

As an Fe-based soft magnetic amorphous alloy, for example, an Fe — Si — B soft magnetic alloy is known, which can be produced by super-quenching a molten metal adjusted to a predetermined composition by a method such as a single-roll liquid quenching method to make the molten metal amorphous. METGLAS (registered trademark) 2605HB1M, 2605SA1 and 2605SA3 of Fe-Si-B-Cr series are commercially available.

In addition, the Fe-based nanocrystalline soft magnetic alloy is obtained by heat-treating an amorphous ribbon obtained in the same manner as the Fe-based soft magnetic amorphous alloy to precipitate (nanocrystalline) an Fe crystal phase or an FeSi crystal phase. For example, FINEMET (registered trademark) FT-3M of Hitachi Metal Co., Ltd. of Fe-Si-B-Cu-Nb system, VITROPERM (registered trademark) 800 of VACUUMSCHMELZE GmbH & Co. KG. and NANOPERM (registered trademark) of MAGNETETEC Gesellschaft fur Magnettechnologie mbH of Fe-B-Zr-Cu system are known.

Any of the above materials is supplied in the form of a strip (strip), tape (ribbon), film or foil, and is usually supplied as a long thin strip having a thickness of ten to several tens μm. Such a thin strip of an Fe-based soft magnetic amorphous alloy or an Fe-based nanocrystalline soft magnetic alloy can be made thinner than an electromagnetic steel sheet, and can reduce eddy current loss. In addition, Fe-based soft magnetic amorphous alloys or Fe-based nanocrystalline soft magnetic alloys have a smaller hysteresis loss than electromagnetic steel sheets, and laminated iron cores using these thin strips have advantages such as excellent soft magnetic properties.

On the other hand, it is known that an Fe-based soft magnetic amorphous alloy containing a precursor of an Fe-based nanocrystalline soft magnetic alloy is an ideal elastoplastic material that does not generally cause strain hardening, and has large plastic deformability and toughness properties, but is apparently hard to cause elongation under uniaxial stress conditions such as a tensile test. Such a ribbon of Fe-based soft magnetic amorphous alloy is extremely hard and has a disadvantage of inferior workability as compared with a crystalline electromagnetic steel sheet, and this is a factor that application to a laminated iron core, in which the ribbon needs to be worked into a predetermined shape, cannot be advanced. Therefore, in addition to punching by a die including a punch and a die of a press machine (hereinafter, only punching is described, and the punching is distinguished from other machining techniques), various machining techniques for obtaining a thin plate having a predetermined shape from a thin strip, such as chemical etching, laser machining, and wire electric discharge machining, have been studied.

Patent document 1 discloses a punching process of an amorphous metal foil. The amorphous metal foil is punched at a predetermined punching speed by using a servo press, thereby suppressing the generation of burrs due to plastic deformation. Patent document 2 discloses etching of a thin strip of an amorphous alloy material. By forming a crystallized region in a predetermined shape in advance on a thin strip and etching the crystallized region, the etching rate is increased. Thereby, the productivity of the etching process is improved.

Documents of the prior art

Patent document

Patent document 1: japanese laid-open patent publication No. 62-9898

Patent document 2: japanese patent laid-open publication No. 55-145174

Disclosure of Invention

Technical problem to be solved by the invention

Fig. 5 is a perspective view showing an example of a thin plate used for the laminated core. In the illustrated example, the sheet 1 is rectangular, having opposing front and back faces 20 and 4 side faces 25 connecting the front and back faces 20. The thin plate 1 obtained from the thin strip is easily bent, but the front and back surfaces 20 of the thin plate 1 are substantially flat in a state of being placed on a stage, and if plastic deformation such as bending does not occur, the shape as shown in the drawing is obtained. The front and back surfaces 20 of the sheet 1 are in the state of a planar body at the time of ribbon formation, and the side surface 25 is a cross section resulting from processing. Fig. 6 is a perspective view showing an example of a laminated core configured by overlapping a plurality of thin plates. In the laminated core 5, several to several thousand thin plates 1 are stacked, and these thin plates are integrally fixed by spot welding, caulking, bonding, or the like between layers.

Fig. 15 is a simplified illustration of a part of a press apparatus for explaining a punching step. Fig. 16 is an enlarged perspective view showing a state of a side surface of a thin plate manufactured by punching. Typically, the shear surface 135 and the fracture surface 138 are formed on the side surface 25 of the sheet 1 by shear stress generated by blanking, and the sagging 131 and the burr 120 associated with plastic deformation are formed in the thickness direction of the sheet 1. In the punching method, a thin strip (not shown) is placed on a die 19 having a punched hole and pressed, and a punch 18 is lowered from above the punched hole, and the thin strip is passed through the punched hole of the die 19 while keeping an interval of about several μm to 100 μm depending on the thickness of the thin strip, and the thin strip is cut by a cutting edge provided on the edge of the front end side of the punch 18 and a cutting edge provided on the edge of the punched hole of the die 19. A burr 120 is formed along the outer periphery of the punch 18 in the thickness direction of the thin plate 1 punched out from the thin strip by the shearing work.

With the method disclosed in patent document 1, although the extent of the burr generated in the thickness direction of the sheet can be suppressed, it is inevitable that the height of the burr increases due to changes over time such as wear of the die and the punch. Originally, the mechanism of the punching process is difficult to eliminate the generation of burrs generated in the thickness direction of the sheet.

In addition, in the method using etching, although burrs in the thickness direction that appear in the thin plate during punching are not generated, a plurality of steps such as resist coating and etching are required, and productivity is low compared to punching, and it is not suitable for producing a large number of thin plates. Laser machining and electric discharge machining are also slow in machining speed and low in productivity as compared with blanking.

Fig. 17 is an enlarged cross section of a laminated core formed by stacking thin plates having burrs. The sheets 1 are stacked with a gap in the plane direction via a resin layer 200 that bonds the layers. The burrs 120 generated on the side surfaces of the thin plates 1 protrude from the front and back surfaces 20, and therefore, the thin plates 1 may contact each other during stacking to cause an electrical short circuit. The short circuit between the thin plates 1 becomes a factor of increasing the eddy current loss, and hinders the reduction of the loss of the laminated core 5. Further, since the burrs 120 are generated at the edges of the thin plates 1, the side surfaces of the laminated core 5 become thicker than the central portion and the volume thereof becomes larger as the number of layers of the thin plates 1 increases, which also affects the dimensional accuracy of the laminated core 5. In addition, the space factor (the ratio of the volume of the thin plates to the volume of the laminated core) of the laminated core 5 may not be increased.

Accordingly, an object of the present invention is to provide an Fe-based soft magnetic amorphous alloy sheet, a laminated core and a rotating electrical machine using the same, and a method for manufacturing the Fe-based soft magnetic amorphous alloy sheet, which can easily reduce the loss of the laminated core.

Means for solving the problems

According to one aspect of the present invention, there is provided an Fe-based soft magnetic amorphous alloy thin plate for a laminated core, comprising: the sheet has: an opposite front and back face; and side surfaces, the thickness of the sheet is 10 to 50 μm, the side surfaces have fracture surfaces inclined from the front surface and the back surface relative to the thickness direction of the sheet, and the side surfaces are in a V shape tapering toward the end in the thickness direction of the sheet.

According to an embodiment of the present invention, the fracture surface is preferably a fracture surface generated by ductile fracture.

According to an aspect of the present invention, it is preferable that all the side surfaces of the thin plate have a V-shape.

According to one embodiment of the present invention, it is preferable that a region of a distance L of 5 μm or more from an end of the V-shape, which is an outer edge of the thin plate, to the inside be a fracture surface.

Further, according to an embodiment of the present invention, a laminated core obtained by laminating Fe-based soft magnetic amorphous alloy thin plates can be provided.

Further, according to an aspect of the present invention, it is possible to provide a rotating electrical machine using a laminated core obtained by laminating and fixing Fe-based soft magnetic amorphous alloy thin plates in a stator or a rotor.

In addition, the Fe-based soft magnetic amorphous alloy thin plate of the present invention can be provided by a method for producing an Fe-based soft magnetic amorphous alloy thin plate, the method comprising: the method includes a step of overlapping a thin strip of the Fe-based soft magnetic amorphous alloy and a non-metallic thin strip having a thickness of 10 to 150 [ mu ] m, and a step of cutting the thin strip of the Fe-based soft magnetic amorphous alloy and the non-metallic thin strip together with a rotary die cutter (rotary die cutter) or a Thomson blade (Thomson blade).

Effects of the invention

The present invention can provide an Fe-based soft magnetic amorphous alloy sheet capable of easily reducing the loss of a laminated core, a laminated core and a rotating electrical machine using the same, and a method for producing the Fe-based soft magnetic amorphous alloy sheet.

Drawings

Fig. 1 is an enlarged perspective view of a side surface of an Fe-based soft magnetic amorphous alloy thin plate according to an embodiment of the present invention.

Fig. 2 is a cross-sectional view of an Fe-based soft magnetic amorphous alloy thin plate according to an embodiment of the present invention, cut in the thickness direction.

Fig. 3 is a configuration diagram showing an embodiment of a processing apparatus for a thin strip of an Fe-based soft magnetic amorphous alloy.

Fig. 4 is a perspective view showing one embodiment of a die cutting roll used in the processing apparatus of fig. 3.

Fig. 5 is a perspective view showing an embodiment of a thin plate used in the laminated core.

Fig. 6 is a perspective view showing an embodiment of a laminated core configured by overlapping a plurality of thin plates.

Fig. 7 is a sectional view showing an embodiment of a section of a laminated core formed by stacking a plurality of thin plates.

Fig. 8 is a perspective view showing another embodiment of the Fe-based soft magnetic amorphous alloy thin plate.

Fig. 9 is a partially enlarged perspective view of the Fe-based soft magnetic amorphous alloy thin plate shown in fig. 8.

Fig. 10 is a perspective view showing another embodiment of a laminated core configured by overlapping a plurality of thin plates.

Fig. 11 is a schematic diagram showing an embodiment of a rotating electric machine using the laminated core of the present invention.

Fig. 12 is a laser microscope photograph of the thin plate of example 1, which was observed on the front and back side surfaces.

Fig. 13 is a laser micrograph showing the side surface side of the cross section of the thin plate of example 1.

Fig. 14 is a laser micrograph showing the surface profile of the thin plate of example 1.

Fig. 15 is a cross-sectional view of a part of a press apparatus for punching a thin strip.

Fig. 16 is an enlarged perspective view of a side surface of a thin plate produced by blanking.

Fig. 17 is a sectional view of a laminated core configured by stacking thin plates having burrs.

Description of the reference numerals

1 Fe-based soft magnetic amorphous alloy thin sheet, 5, 10 laminated iron core, 6 convex part, 7 circular part, 18 punch, 19 die, 20 front and back of thin sheet, 25 side of thin sheet, 30 inclined surface of thin sheet, 85 fracture surface by ductile fracture, 120 burr, 131 sag, 135 shear surface, 138 fracture surface, 200 resin layer, 260 stator winding, 280 rotating electrical machine, 290 permanent magnet, 300 reel wound with Fe-based soft magnetic amorphous alloy ribbon, 301 Fe-based soft magnetic amorphous alloy ribbon, 305 reel wound with nonmetal ribbon, 306 nonmetal ribbon, 350 die cutting roll, 351 cutter blade, 355 anvil roll, 360 reel wound with processed Fe-based soft magnetic amorphous alloy ribbon, 370 container for recovering processed thin sheet.

Detailed Description

The embodiments of the present invention will be specifically described below, but the present invention is not limited to these. In some or all of the drawings, unnecessary portions in the description are omitted, and some portions are illustrated in an enlarged or reduced form for ease of description. In the present specification, the numerical range expressed by the term "to" means a range including numerical values described before and after the term "to" as a lower limit value and an upper limit value. In the present specification, the term "step" includes not only an independent step but also a step that can achieve a desired purpose of the step even when the step cannot be clearly distinguished from other steps.

Fig. 1 is an enlarged perspective view of a side surface of an Fe-based soft magnetic amorphous alloy sheet according to an embodiment of the present invention. The sheet according to one embodiment of the present invention may have, for example, the same form as that of fig. 5. The side surface 25 of the thin plate 1 is a processed cross section of the inclined surface 30 inclined from the front surface 20 side to the thickness direction (z direction in the drawing) of the thin plate 1. Fig. 2 is a sectional view of the thin plate 1 cut in the thickness direction. In a cross section (xz plane) of the thin plate 1 in the thickness direction, the side surface 25 of the thin plate 1 is in a V shape tapering toward the end. In the inclined surface 30, the range of the distance L from the V-shaped end portion to the front and back surfaces 20 is a fracture surface 85 caused by ductile fracture. Here, ductile fracture refers to fracture accompanied by plastic deformation, and when the structure of a fracture surface is observed with an electron microscope, traces of fine deformation are observed in the fracture surface, and a fracture surface having a mode different from that of brittle fracture and fatigue fracture appears. Since the inclined surfaces are continuous from the front and back surfaces 20 facing each other, it is not necessary to separately overlap the front and back surfaces 20 of the thin plates 1 to form a laminated core, and handling is easy.

The majority of the inclined surface 30 is a fracture surface 85. The fracture surface 85 is microscopically a discontinuous surface formed by surfaces having different inclinations, but may be macroscopically a surface that is separated from the front and back surfaces 20 as going from the flat front and back surfaces 20 to the edge of the sheet. The side surface 25 includes not only an inclined surface that is linearly inclined as shown in the drawing when a cross section in the thickness direction of the thin plate 1 is observed, but also an inclined surface that is curved and a wave (undulation) form. In addition, the inclined surface continuous with one of the front and back surfaces and the inclined surface continuous with the other of the front and back surfaces may be different in the form of the inclined surface and/or the region of the fracture surface 85 within the range of the distance L from the end of the V-shape. In addition, the fractured surface may be a vein-like tissue. It is known that the vein-like structure is a characteristic structure of an amorphous alloy and can be observed in a fracture plane generated by drawing. The pulse-like tissue is generated as a result of local temperature rise due to heat insulation and viscous and fluid deformation.

In the sheet 1 formed by punching as described above, the front and back surfaces 20 and the side surfaces 25 (the fracture surfaces 138) form an acute angle due to the burr 120, and protrude toward the front and back surfaces 20. In contrast, in the sheet 1 of the present invention, no burr protrudes toward the front and back surfaces 20, and the angle formed by the front and back surfaces 20 and the side surface 25 (inclined surface 30) is an obtuse angle. Fig. 7 shows a cross section of a laminated core 5 formed by stacking such thin plates 1. As shown in the drawing, the laminated core 5 in which the increase of the eddy current loss due to the short circuit is suppressed can be obtained without generating the interference such as the contact between the thin plates 1 due to the burr in the laminated core 5. In addition, although the V-shaped portion may be a part of the side surface 25 of the sheet 1, the circumferential length of the V-shaped portion with respect to the side surface is preferably 50% or more, and more preferably 80% or more.

It is difficult to eliminate the occurrence of burrs protruding in the thickness direction, which are generated at the edges of the thin plates, in the punching process. Therefore, the present inventors have conducted various studies on a processing technique for obtaining a thin plate having a predetermined shape from a thin strip. Among them, the following findings were obtained: by cutting the thin strip using a thomson knife or a rotary die cutter, the generation of burrs protruding in the thickness direction of the thin strip can be prevented. By a combination of the thomson blade and a base (receiving table) described later or a combination of the die cutting roll and the anvil roll, the thin strip is crushed by the blade edge and plastically deformed and broken, so that burrs protruding in the thickness direction, which are generated in the shearing process, are not generated in the obtained thin plate, and the side surface 25 is formed by the inclined surface 30 having the breaking surface 85, and has a V-shape with a tapered tip as shown in fig. 1.

In the laminated core, the thin plate is preferably thin in thickness in order to reduce eddy current loss. On the other hand, as the thickness of the thin plate is reduced, the duty factor tends to be reduced by the influence of surface roughness, unevenness, and the like. Therefore, the thickness of the Fe-based soft magnetic amorphous alloy thin plate (ribbon) is preferably 10 μm or more and 50 μm or less. More preferably 12 μm or more, and still more preferably 15 μm or more. Further, it is more preferably 45 μm or less, and still more preferably 40 μm or less. As the thin ribbon of the Fe-based soft magnetic amorphous alloy, the commercially available METGLAS (registered trademark) 2605SA1 and the like can be suitably used.

The method for producing the Fe-based soft magnetic amorphous alloy sheet according to the present invention will be specifically described below with reference to the drawings. Fig. 3 is a structural view of a thin strip processing apparatus including a rotary die cutter. The rotary die cutter is constituted by a cylindrical die cutting roll (die cut roll)350 and an anvil roll (anvil roll)355, and a sheet-like work is inserted between the die cutting roll 350 and the anvil roll 355 while rotating them. The work is obtained by superposing a thin ribbon of Fe-based soft magnetic amorphous alloy and a thin ribbon of non-metal, and the thin ribbon of Fe-based soft magnetic amorphous alloy 301 wound from a reel (spool)300 is superposed on the front and back surfaces of the thin ribbon of Fe-based soft magnetic amorphous alloy 306 wound from a reel 305, and the thin ribbon of Fe-based soft magnetic amorphous alloy 301 is fed to a rotary die cutter with the thin ribbon of non-metal 306 sandwiched therebetween. Fig. 4 is an external perspective view of the die-cutting roll. The die-cutting roll 350 has a plurality of cutting blades 351 on its surface. The edge of the cutter blade 351 has a width of several μm to several tens of μm and is flat, and the workpiece supplied to the rotary die cutter is pressed against the surface of the anvil roll 355 by the cutter blade 351, whereby the thin strip 301 of the Fe-based soft magnetic amorphous alloy is crushed and broken. The thin plate 1 cut out from the workpiece is collected in the container 370 together with the nonmetallic end material cut out from the workpiece. The work passing through the rotary die cutter is taken up on a reel 360.

The non-metallic ribbon 306 functions as a cushion material, and may be, for example, a film-like resin having a thickness of 10 to 150 μm, japanese paper, or western paper. The resin is preferably polyethylene, polyvinyl chloride, acrylic resin, polyethylene terephthalate, or polycarbonate.

Even if the cutting knife of the die cutting roller is worn, no burr protruding in the thickness direction of the thin plate is generated, so that the thin plate with the V-shaped side surface can be stably manufactured. Further, when the abrasion of the cutting blade progresses, the thin plate cannot be cut, and a part of the end portion is easily connected to the thin strip of the Fe-based soft magnetic amorphous alloy. By observing the state of separation, the cutting blade can be corrected as an index of the degree of wear of the cutting blade, and therefore, maintenance and management of the thin strip processing apparatus become easy. The present invention is not limited to this, and a cutting method using a thomson knife may be used.

Thin plates obtained through a step of imparting a certain shape to a thin strip of Fe-based soft magnetic amorphous alloy can be stacked and integrated by an adhesive or the like. In the laminating step, the following method is preferred: an alignment jig and a pressing plate corresponding to the shape of the thin plate are prepared, the thin plates of a desired number of laminated pieces are stacked in the alignment jig, and the pressing plates are stacked and integrated on the upper and lower sides of the alignment jig. In the bonding between the Fe-based amorphous alloy thin plates, the resin layer is preferably formed uniformly, but when a necessary bonding strength can be obtained, the resin layer may be formed locally. The application (supply) of the resin to the Fe-based amorphous alloy thin plate may be performed by dropping or spraying a liquid resin onto the thin plate, or by immersing the thin plate in a liquid resin. Further, the Fe-based soft magnetic amorphous alloy thin plate may be laminated and integrated through a step of imparting a shape after a method of imparting a resin by using an applicator (coating device) before processing or immersing the thin strip in a liquid resin.

The resin used for bonding the sheets is preferably an epoxy resin or an acrylic resin. Among these resins, resins having high heat resistance are more preferable.

The thinner the thickness of the resin layer between the sheets is, the higher the space factor of the laminated core can be, and therefore, this is preferable. In order to obtain a desired adhesive strength and a high fill factor (80% to 98%), the thickness of the resin layer between the sheets is preferably about 1 μm to 5 μm, and more preferably in the range of 1 μm to 3 μm. Since no burr protruding in the thickness direction is generated at the edge of the thin plate, the thickness of the resin layer can be reduced, and the increase in volume of the edge portion of the laminated core can be suppressed even when the thickness of the resin layer is reduced.

Fig. 8 is a perspective view of another embodiment of the Fe-based soft magnetic amorphous alloy thin plate. The illustrated thin plate 1 is used for a laminated core of a rotating electrical machine, and has a circular ring portion 7 having a plurality of convex portions 6 provided rotationally symmetrically along the inner periphery thereof. Fig. 9 is a partially enlarged perspective view of the thin plate. The illustrated thin plate 1 has a shape having a plurality of side surfaces 25 on the inner diameter side. Such a thin plate 1 is also produced by the same method as the thin plate shown in fig. 5, and thus, burrs protruding in the thickness direction do not occur at the edges of the thin plate 1, and the side surfaces 25 of the thin plate 1 can be formed into a V-shape tapered toward the end portions while being inclined surfaces inclined with respect to the thickness direction of the thin plate 1 from the front and back surfaces 20 as shown in fig. 1. The shape of the sheet in the present invention is not particularly limited, and various forms are possible.

Fig. 10 is a perspective view of a laminated core formed by stacking Fe-based soft magnetic amorphous alloy thin plates. The laminated core 10 shown in the figure is used as a stator of a rotating electric machine, and several hundreds to several thousands of thin plates 1 are stacked. The circular ring portion 7 is used as a back yoke of the stator, and the convex portion 6 serves as a pole tooth. The obtained laminated core 10 can also be a laminated core in which an increase in eddy current loss due to a short circuit between the thin plates 1 is suppressed.

Fig. 11 is a schematic diagram showing an example of a rotating electric machine using the laminated core 10 of the present invention. As shown in fig. 11, a rotating electric machine 280 according to the present invention includes a rotor on the inner diameter side of a stator (laminated core) 10 with a gap therebetween. A plurality of permanent magnets 290 are arranged on the outer periphery of the rotor. The permanent magnets 290 are magnetized so that the side facing the stator 10 becomes the N pole or the S pole, and are arranged at equal angles so that the polarities of the adjacent permanent magnets 290 are alternately opposite to each other. In the embodiment shown in fig. 11, the rotor has 8 poles, but the number of magnetic poles is not limited thereto.

The pole teeth 6 of the stator 10 are provided with stator windings 260, and a three-phase ac current based on the positions of the magnetic poles of the rotor is supplied to the stator windings 260, so that the stator generates a rotating magnetic field. The rotating electric machine operates as a rotating electric motor by using the permanent magnet 260 of the rotor and the rotating magnetic field. In the present invention, a rotating electrical machine capable of operating with high efficiency can be realized by using a laminated core as a stator, the laminated core using a thin Fe-based soft magnetic amorphous alloy sheet having a thickness of 10 to 50 μm and no burr in the thickness direction.

[ examples ]

As a ribbon of the Fe-based soft magnetic amorphous alloy, Metglas (registered trademark) 2605SA1 manufactured by hitachi metal co. The thin strip is in the shape of a long strip, the thickness of the strip is 25 micrometers and 32 micrometers, and the width of the strip is 30 mm. The thin strip of the Fe-based soft magnetic amorphous alloy was fractured using a thomson knife or a die cutting roll to produce a thin plate having a shape shown in fig. 8. The outer dimensions of the sheet were 22mm in outer diameter and 10mm in inner diameter.

(example 1)

And (3) making the thin strip of the Fe-based soft magnetic amorphous alloy into a thin plate by using the rotary die cutting machine. A thin sheet was produced by sandwiching a thin strip of an Fe-based soft magnetic amorphous alloy having a thickness of 25 μm between polyethylene films having a thickness of 13 μm as a buffer material to form a work, and passing the work through an anvil roll and a die-cutting roll in close proximity. The cutting edge of the cutting blade of the die-cutting roll has a width of 15-30 μm and is flat, and the angle of the cutting edge is 30 degrees.

(example 2)

A thin plate was produced in the same manner as in example 1, except that a thin strip of an Fe-based soft magnetic amorphous alloy having a thickness of 32 μm was used.

(example 3)

A thin strip of a 25 μm thick Fe-based soft magnetic amorphous alloy was cut with a Thomson knife to prepare a thin plate. The cutting device for mounting the Thomson knife comprises: a driving mechanism for reciprocating the Thomson knife up and down; and a base having a flat cutting surface on which the thin strip is disposed, and capable of breaking the thin plate by moving the Thomson knife to the cutting surface. A thin plate was produced by sandwiching a thin strip of Fe-based soft magnetic amorphous alloy as a work piece between polyethylene films having a thickness of 100 μm as a buffer material, and applying a pressure of 150N with a thomson knife to break the thin strip. The thomson knife also has a tip width of 20 μm and is flat with a tip angle of 45 °.

The side surfaces of the sheets obtained in examples 1 to 3 were observed from the front and the back sides using a laser microscope VK-X1000 manufactured by KEYENCE. Fig. 12 shows a laser microscope photograph obtained by observing the front surface and the back surface of the thin plate of example 1 on the side surface side. Each thin plate was cut, and the side surface of the cut surface embedded in the resin was exposed by polishing and observed. Fig. 13 shows a laser microscope photograph obtained by observing the side surface side of the cross section (cross section) of the thin plate of example 1. From the observation photographs obtained, the side surfaces thereof each have an inclined surface continuous from the front surface and the back surface, the entire inclined surface is constituted by a fracture surface due to ductile fracture, and the sectional shape is a tapered V-shape. In addition, no burr protruding in the thickness direction, which is generated in the shearing process, was confirmed. The distance L from the V-shaped end of the side face was measured for the fracture face by observing the front and back faces of the sheet, and the distance that becomes the minimum and maximum is shown in table 1 as the fracture face distance L.

[ Table 1]

The Fe-based soft magnetic amorphous alloy sheet of the present invention has a fracture surface in a region of approximately 10 to 100 μm on the side surface, and the cross section thereof is tapered toward the end. The thin plate of example 1 was observed at a magnification of 50 times using a laser microscope VK-X1000 manufactured by keyence with a 270 μm × 202 μm area including the front and back surfaces and the inclined surface as an evaluation area. Fig. 14 shows the surface profile of the sheet. Since no burr protruding in the thickness direction was observed at the corner formed by the front and back surfaces 20 and the inclined surface 30, it was found that, in the laminated core obtained by laminating the thin plates of the present invention, an electrical short circuit between the layers was less likely to occur, and the loss of the laminated core could be easily reduced.