In 2018, Matsushita will start production of a highly efficient white household appliance motor using the new soft magnetic material “NANOMET†as a stator. This trial produced a small motor with a stator diameter of about 70 mm, which was reduced by about 70% compared with the iron loss of ordinary electromagnetic steel plates (Fig. 1).
The results of estimating the iron loss and efficiency of a white-appliance motor with a stator diameter of 125 mm and a rated output of 40 W using a NAOOMET result in almost the same loss reduction effect.
Considering both high magnetic permeability and high saturation magnetic flux density
Figure 1: Iron loss can be reduced by about 70%
Matsushita used the new magnetic material “NANOMET†developed by Tohoku University as a stator and trial-produced a high-efficiency motor (a). The iron loss is reduced by about 70% (b) as compared with the case of using an ordinary magnetic steel plate. This increases motor efficiency by 6 percentage points. Based on this result, the iron loss and efficiency of a home appliance motor with a diameter of 125 mm and a rated output power of 40 W when using Nanomet were estimated, and the result was expected to achieve the same loss reduction effect. (Photography: Panasonic)
NANOMET was developed by the R&D team of Professor Makino Akira and others from the Institute of Metal Materials, Tohoku University in Japan. Iron loss can be reduced because it can have both high magnetic permeability and high saturation magnetic flux density. NANOMET's saturation magnetic flux density is 1.8 to 1.9T, which is comparable to electromagnetic steel plates (silicon steels), and can achieve magnetic permeability higher than a single digit more than electromagnetic steel plates (Fig. 2).
Figure 2: High saturation magnetic flux density and high magnetic permeability can be achieved by making nanocrystals
NANOMET is made by melting a FeSiBPCu-based alloy with a high iron concentration, forming it into an amorphous state by a "quenching method", and heating it to about 400°C. Due to the action of phosphorus and copper contained in the alloy, iron "buds" having a grain size of several nm appear in an amorphous state. The heat treatment causes the ferrite to form nanocrystals (a), and as a result, a high saturation magnetic flux density and a high magnetic permeability (b) can be achieved. At present, it has been possible to manufacture a 120 mm wide NAOOMET(c). (Figures (a) and (b) were produced by Nikkei Electronics based on materials from Tohoku University)
The reason why both the high magnetic permeability and the high saturation magnetic flux density can be achieved is that an amorphous alloy composition having a concentration of iron (Fe) of 90% or more is found, and further, iron becomes a nanoparticle. Specifically, nanocrystallization is achieved by the following steps: First, a FeSiBPCu alloy with a higher iron concentration is melted at a high temperature of about 1200[deg.] C. which exceeds its melting point. It is then cooled by the "liquid quenching method" to form an amorphous state. In fact, the FeSiBPCu alloy is melted in a vacuum and sprayed onto a high-speed rotating copper roll. The copper roller was used for cooling to form a thin strip-shaped amorphous alloy having a thickness of 20 μm to 30 μm.
At this time, iron "buds" having a particle size of 3 nm or less appear due to the action of phosphorus and copper contained in the alloy. This state is called Hetero Amorphous. After being processed into a desired shape in a heterogeneous amorphous state, a heat treatment at about 400° C. is performed to form nanocrystals.
NANOMET does not contain expensive metals, so it is estimated that the cost of mass production can be controlled at the same level as the previous material.
Also available in rolls
Heteromorphous FeSiBPCu-based alloys can only be made into thin strips a few millimeters wide. Since then, it has gradually expanded to 50mm and 80mm, and in June 2014, it has increased to 120mm wide, making it practical. By changing the manufacturing conditions and the like, the magnetic properties such as the coercive force and the saturation magnetic flux density are not deteriorated even when the width is 120 mm.
By expanding the width of NAOOMET, it can be used for large transformers such as telephone poles and home appliance reactors in addition to motor applications. In fact, Tohoku University has used NAOOMET to prototype transformers and reactors (Figure 3). In the future, we plan to expand the range of applicable products and introduce devices that can produce about 170 mm wide rolls of material.
Figure 3: Uses beyond the motor will also be developed
In addition to the stator of the motor, NANOMET can also be used as a core material for pole transformers of power transmission lines and reactors for white household appliances. Trial production has been completed.
Panasonic also plans to apply it to inductors for digital home appliances such as personal computers and smart phones. In these applications will be provided heterogeneous amorphous magnetic FeSiBPCu alloy powder, rather than NANOMET Note 1).
Note 1) Make the melted material using "atomization method".
Companies other than Panasonic have also paid high attention to NAOMET. Makino said that it will cooperate with the top five companies and set up a venture company to manufacture nano- and hetero-amorphous magnetic powders in 2015. (Reporter: Ujinjin)
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