Stator Magnetic Core Brushless Motor Apparatus, System and Methods

A method of providing a DC brushless motor, comprising:

• insulating a stator magnetic core from a stator coil with one or more insulating layers;
• isolating the stator magnetic core from the stator coil so that the stator magnetic core does not come in physical contact with the stator coil;
• curing the stator magnetic core with a nano-epoxy curing agent;
• machining the stator magnetic core in a cooling emulsion;
• and forming the stator magnetic core with an iron-based amorphous material containing at least one element selected from the group consisting of:
• Co and V.

A method of configuring a stator magnetic cote, comprising steps for:

• separating a stator magnetic core from a stator coil with one or more insulating layers;
• isolating the stator magnetic core from the stator coil so that the stator magnetic core does not come in physical contact with the stator coil;
• disposing the stator coil inside the stator magnetic core;
• and coinciding an axes of a rotor spindle with the axes of the stator coil and the stator magnetic core.

A computer implemented method for heat treating a stator magnetic core, having one or more computers including computer-usable readable storage medium having computer readable program code embodied thereon for causing a computer system to receive one or more signals from one or more sensors for performing one or more process control manufacturing steps for forming a stator magnetic core by raising a first temperature to 310° C.;

• holding the first temperature for about 20-25 minute, raising the first temperature to a second temperature at 345° C.;
• holding the second temperature for about 15-20 min;
• raising the second temperature to a third temperature at 385° C.;
• holding the third temperature for about 30-35 min;
• powering off;
• cooling together with a fourth temperature of about 120° C., and tapping off.

A method of forming a stator magnetic core, comprising steps for:

• creating a compound of iron-based amorphous material containing at least one element selected from the group consisting of:
• Co and V, and the compound having a composition by weight percentage of Co 0.8-1.4%, V 0.6-1.2%, B 2.7-3.3%, Si 6.5-8%, and Fe;
• conforming a material mass workpiece from the compound;
• applying a vacuum heat treatment process to the workpiece;
• raising a first temperature to 310° C.;
• holding the first temperature for 20-25 min at first;
• raising the first temperature to a second temperature at 345° C.;
• holding the second temperature for about 15-20 min;
• raising the second temperature to a third temperature at 385° C.;
• holding the third temperature for about 30-35 min;
• powering off, cooling together to a fourth temperature of 120° C.;
• and tapping off;
• curing the stator magnetic core by raising the stator magnetic core workpiece to a first temperature of about 80-90° C.;
• putting the stator magnetic core workpiece into a vacuum dipping box with a curing agent of V852-12A/B nano-epoxy adhesive;
• transferring the stator magnetic core to a 110° C. oven five (5) hours later;
• keeping the stator magnetic core in the 110° C. oven for two (2) hours;
• shaping and machining the stator magnetic core by cutting the stator magnetic core workpiece by a 3500 Ypm carborundum wheel under the protection of a cooling emulsion;
• forming a nanocrystalline microstructure within a portion of the stator magnetic core with grain sizes of about 100 nanometers or less and having a saturation induction of at least 1.5 Tesla (T) and low core loss bulk amorphous metal magnetic components, wherein the low core loss bulk amorphous metal magnetic components are bonded by impregnation with the nano-epoxy adhesive to provide stator magnetic core grains having a flux density of about 1.3 Tesla (T) and core loss of less than or equal to about 5.7 watts-per-kilogram of amorphous metal material;
• and isolating the stator magnetic core from the stator coil with one or more insulating layers so that the stator magnetic core does not come in physical contact with the stator coil by disposing the stator coil inside the stator magnetic core separated by the one or more insulating layers.