High performance bulk metal magnetic component
OwnerNicholas J. Decristofaro, Gordon E. Fishinventors
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Abstract
A high performance bulk magnetic component includes a plurality of layers of crystalline, ferromagnetic metal strips adhesively bonded together to form a polyhedrally shaped part. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it exhibits a core-loss less than “L” wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively. Performance characteristics of the high performance bulk magnetic component of the present invention are significantly better when compared to silicon-steel components operated over the same frequency range.
Claims50
A high performance, low core loss bulk magnetic component comprising a plurality of substantially similarly shaped layers of crystalline, ferromagnetic metal strips adhesively bonded together by an adhesive bonding means to form a laminated polyhedrally shaped part, wherein the ferromagnetic metal strips include an iron-base alloy containing 4-11 weight percent Si, and wherein said magnetic component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0135 f(Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
A high performance, low core loss bulk magnetic component comprising a plurality of substantially similarly shaped layers of crystalline, ferromagnetic metal strips adhesively bonded together by an adhesive bonding means to form a laminated polyhedrally shaped part, wherein the ferromagnetic metal strips include an Fe—Ni base alloy containing 35-70 weight percent Ni, and wherein said magnetic component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
A high performance poleface magnet comprising at least one magnetic component, each magnetic component including a plurality of substantially similarly shaped layers of crystalline, ferromagnetic metal strips bonded together by an adhesive bonding means to form a polyhedrally shaped part wherein said magnetic component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0135 f(Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
A high performance poleface magnet comprising at least one magnetic component, each magnetic component including a plurality of substantially similarly shaped layers of crystalline, ferromagnetic metal strips bonded together by an adhesive bonding means to form a polyhedrally shaped part, wherein the ferromagnetic metal strips include an iron base alloy containing 4-11 weight percent Si, and wherein said magnetic component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
A high performance poleface magnet comprising at least one magnetic component, each magnetic component including a plurality of substantially similarly shaped layers of crystalline, ferromagnetic metal strips bonded together by an adhesive bonding means to form a polyhedrally shaped part, wherein the ferromagnetic metal strips include an Fe—Ni base alloy containing 35-70 weight percent Ni, and wherein said magnetic component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
A method of constructing a high performance bulk magnetic component comprising:
- (a) cutting crystalline, ferromagnetic metal strip material comprised of at least an iron base alloy containing 4-11 weight percent Si to form a plurality of strips having a predetermined length;
- (b) stacking the strips to form a bar of stacked ferromagnetic metal strip material;
- (c) impregnating the stacked bar with an adhesive bonding means and activating the adhesive bonding means to laminate the cut strips;
- and
- (d) cutting the stacked bar at predetermined lengths to provide a plurality of polyhedrally shaped magnetic components.
A method of constructing a high performance bulk magnetic component comprising:
- (a) cutting crystalline, ferromagnetic metal strip material comprised of at least an iron base alloy containing 4-11 weight percent Si to form a plurality of strips having a predetermined length;
- (b) stacking the strips to form a bar of stacked ferromagnetic metal strip material;
- (c) impregnating the stacked bar with an adhesive bonding means and activating the adhesive bonding means to laminate the cut strips;
- and
- (d) cutting the stacked bar at predetermined lengths to provide a plurality of polyhedrally shaped magnetic components, wherein said low-loss high performance bulk magnetic component when excited at a frequency f to a peak induction level Bmax has a core-loss less than L wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000282 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
A method of constructing a high performance bulk magnetic component comprising:
- (a) winding crystalline, ferromagnetic metal strip material comprised of at least an iron base alloy containing 4-11 weight percent Si about a mandrel to form a generally rectangular core having generally radiused corners;
- (b) impregnating the generally rectangular core with an adhesive bonding means and activating the adhesive bonding means to laminate the layers;
- (c) cutting the short sides of the generally rectangular core to form two polyhedrally shaped magnetic components;
- (d) removing the generally radiused corners from the long sides of the generally rectangular core;
- and
- (e) cutting the long sides of the generally rectangular core to form a plurality of magnetic components.
A method of constructing a high performance bulk magnetic component comprising the steps of:
- (a) stamping crystalline, ferromagnetic metal strip feedstock comprised of at least an iron base alloy containing 4-11 weight percent Si to form a plurality of laminations having a predetermined shape;
- (b) stacking and registering the laminations to form a stack having a three-dimensional shape;
- and
- (c) applying and activating adhesive means to adhere the laminations to each other to form the component, wherein the component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
A method of constructing a high performance bulk magnetic component comprising:
- (a) cutting crystalline, ferromagnetic metal strip material comprised of at least an Fe—Ni base alloy containing 35-70 weight percent Ni to form a plurality of strips having a predetermined length;
- (b) stacking the strips to form a bar of stacked ferromagnetic metal strip material;
- (c) impregnating the stacked bar with an adhesive bonding means and activating the adhesive bonding means to laminate the cut strips;
- and
- (d) cutting the stacked bar at predetermined lengths to provide a plurality of polyhedrally shaped magnetic components.
A method of constructing a high performance bulk magnetic component comprising:
- (a) cutting crystalline, ferromagnetic metal strip material comprised of at least an Fe—Ni base alloy containing 35-70 weight percent Ni to form a plurality of strips having a predetermined length;
- (b) stacking the strips to form a bar of stacked ferromagnetic metal strip material;
- (c) impregnating the stacked bar with an adhesive bonding means and activating the adhesive bonding means to laminate the cut strips;
- and
- (d) cutting the stacked bar at predetermined lengths to provide a plurality of polyhedrally shaped magnetic components, wherein said low-loss high performance bulk magnetic component when excited at a frequency f to a peak induction level Bmax has a core-loss less than L wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000282 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
A method of constructing a high performance bulk magnetic component comprising:
- (a) winding crystalline, ferromagnetic metal strip material comprised of at least an Fe—Ni base alloy containing 35-70 weight percent Ni about a mandrel to form a generally rectangular core having generally radiused corners;
- (b) impregnating the generally rectangular core with an adhesive bonding means and activating the adhesive bonding means to laminate the layers;
- (c) cutting the short sides of the generally rectangular core to form two polyhedrally shaped magnetic components;
- (d) removing the generally radiused corners from the long sides of the generally rectangular core;
- and
- (e) cutting the long sides of the generally rectangular core to form a plurality of magnetic components.
A method of constructing a high performance bulk magnetic component comprising the steps of:
- (a) stamping crystalline, ferromagnetic metal strip feedstock comprised of at least an Fe—Ni base alloy containing 35-70 weight percent Ni to form a plurality of laminations having a predetermined shape;
- (b) stacking and registering the laminations to form a stack having a three-dimensional shape;
- and
- (c) applying and activating adhesive means to adhere the laminations to each other to form the component, wherein the component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0135 f (Bmax)1.9+0.000108 f1.6 (Bmax)1.92, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.
Dependencies are inferred from the claim text.