Method of manufacturing electromagnetic devices using kinetic spray
AssigneeFord Motor Company
InventorsFranco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Abstract
A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.
Claims46
A method of producing a permanent magnet comprising the steps of:
- kinetically spraying an admixture of a magnetic material and a binder material, the kinetic spraying occurring at a temperature substantially below the melting temperature of the magnetic material, said kinetically sprayed admixture forming a solid permanent magnet.
A method of producing a permanent magnet comprising the steps of:
- preparing an admixture of magnetic material and binder material, said admixture having a particle size less than 325 mesh;
- heating a carrier gas to a temperature substantially below the melting point of either component of said admixture;
- introducing said admixture into said carrier gas;
- spraying said admixture atop a ductile carrier, said admixture adhering to said carrier;
- forming a solid permanent magnet;
- and
- applying an electric field to said magnet to create a permanent magnetic moment.
A method of producing a permanent magnet attached to a component of an electric machine comprising the steps of:
- preparing an admixture of magnetic material and binder material;
- heating a carrier gas to a temperature substantially below the melting point of either component of said admixture;
- introducing said admixture into said carrier gas;
- spraying said admixture atop said component, said admixture adhering to said component;
- forming a solid permanent magnet adhered to said component;
- applying an electric field to said magnet to create a permanent magnetic moment.
An electric machine comprising:
- a kinetically sprayed permanent magnet material and a binder material forming a composite admixture having microstructures of permanent magnet material embedded in the binder material, said admixture having a permanent magnetic moment.
A method of manufacturing electric machines comprising the steps of:
- kinetically spraying a powdered admixture of magnetic material and ductile binder material on to a substrate;
- applying a concentrated magnetic field to said sprayed admixture to cause said sprayed admixture to cause magnetic dipole alignment in said sprayed admixture.
Dependencies are inferred from the claim text.