Bifilar layer-insulated magnetic core and method for the production of a wound nanocrystalline magnetic core

A method for the production of a wound nanocrystalline magnetic core comprising:

• providing a nanocrystalline metal strip consisting of
• (Fe1-aMa)100-x-y-z-α-βCuxSiyBzM′αXβ,
• where
• 0≤a≤0.4,
• 0.1≤x≤3 at. %,
• 0≤y≤30 at. %,
• 0 at. % ≤z≤25 at. %,
• 0.1 at. % ≤α≤30 at. %,
• β≤5 at. %,
• M is Co and/or Ni,
• M′ is one or more elements from the group consisting of V, Nb, Ta, Mo, W, Zr, Hf, Ti, Cr and Mn,
• X is one or more from the group consisting of C, Ge and P, including less than 2 at. % of customary impurities, the metal strip being pre-wound to form a coil,
• providing an insulating foil that is coated on at least one side with an adhesive,
• applying the adhesive to the nanocrystalline metal strip to laminate the insulating foil onto the metal strip and to stabilise the metal strip as it is wound off the coil,
• bifilar winding the laminated nanocrystalline metal strip and the insulating foil to form a bifilar, layer-insulated coil,
• wherein the insulating foil is provided on a removable carrier strip, the carrier strip is removed from the adhesive and the adhesive is applied to the nanocrystalline metal strip to laminate the insulating foil onto the metal strip.

A method for the production of a wound nanocrystalline magnetic core comprising:

• providing a nanocrystalline metal strip consisting of
• (Fe1-aMa)100-x-y-z-α-βCuxSiyBzM′αXβ,
• where
• 0≤a≤0.4,
• 0.1≤x≤3 at. %,
• 0≤y≤30 at. %,
• 0 at. % ≤z≤25 at. %,
• 0.1 at. % ≤α≤30 at. %,
• β≤5 at. %,
• M is Co and/or Ni,
• M′ is one or more elements from the group consisting of V, Nb, Ta, Mo, W, Zr, Hf, Ti, Cr and Mn,
• X is one or more from the group consisting of C, Ge and P, including less than 2 at. % of customary impurities, the metal strip being pre-wound to form a coil,
• providing an insulating foil that is coated on at least one side with an adhesive,
• applying the adhesive to the nanocrystalline metal strip to laminate the insulating foil onto the metal strip and to stabilise the metal strip as it is wound off the coil,
• bifilar winding the laminated nanocrystalline metal strip and the insulating foil to form a bifilar, layer-insulated coil, wherein the bifilar winding takes place at a winding speed s where s ≥1 m/min.

A method for the production of a wound nanocrystalline magnetic core comprising:

• providing a nanocrystalline metal strip consisting of
• (Fe1-aMa)100-x-y-z-α-βCuxSiyBzM′αXβ,
• where
• 0≤a≤0.4,
• 0.1≤x≤3 at. %,
• 0≤y≤30 at. %,
• 0 at. % ≤z≤25 at. %,
• 0.1 at. % ≤α≤30 at. %,
• β≤5 at. %,
• M is Co and/or Ni,
• M′ is one or more elements from the group consisting of V, Nb, Ta, Mo, W, Zr, Hf, Ti, Cr and Mn,
• X is one or more from the group consisting of C, Ge and P, including less than 2 at. % of customary impurities, the metal strip being pre-wound to form a coil,
• providing an insulating foil that is coated on at least one side with an adhesive,
• applying the adhesive to the nanocrystalline metal strip to laminate the insulating foil onto the metal strip and to stabilise the metal strip as it is wound off the coil,
• bifilar winding the laminated nanocrystalline metal strip and the insulating foil to form a bifilar, layer-insulated coil, wherein the relative positions of a central line of the insulating foil and a central line of the nanocrystalline metal strip are measured optically and if the predetermined maximum deviation is exceeded the relative position of the insulating foil is corrected by a regulating mechanism.

A method for the production of a wound nanocrystalline magnetic core comprising:

• providing a nanocrystalline metal strip consisting of
• (Fe1-aMa)100-x-y-z-α-βCuxSiyBzM′αXβ,
• where
• 0≤a≤0.4,
• 0.1≤x≤3 at. %
• 0≤y≤30 at. %,
• 0 at. % ≤z≤25 at. %,
• 0.1 at. % ≤α≤30 at. %,
• β≤5 at. %,
• M is Co and/or Ni,
• M′ is one or more elements from the group consisting of V, Nb, Ta, Mo, W, Zr, Hf, Ti, Cr and Mn,
• X is one or more from the group consisting of C, Ge and P, including less than 2 at. % of customary impurities, the metal strip being pre-wound to form a coil,
• providing an insulating foil that is coated on at least one side with an adhesive,
• applying the adhesive to the nanocrystalline metal strip to laminate the insulating foil onto the metal strip and to stabilise the metal strip as it is wound off the coil,
• bifilar winding the laminated nanocrystalline metal strip and the insulating foil to form a bifilar, layer-insulated coil,
• wherein the insulating foil comprises a plastic foil, and
• wherein the plastic foil has an average width Bk and the nanocrystalline strip has an average width Bm, where Bk >Bm, and the plastic foil has an overhang on both sides after bifilar winding.