# US 2017/0288478 A9 · Stator Magnetic Core Brushless Motor Apparatus, System and Methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2017/0288478 A9 - Document ID: US20170288478A9 - Status: Published application - Kind: A9 - Application number: 15/221,526 - Filed: 2016-07-27 - Published: 2017-10-05 - Earliest claimed: 2015-07-28 - Assignees: Canas Sun, Inc. - Inventors: Hongxin Liang - Web page: https://patentgrep.com/patent/US20170288478A9 ## CPC - H02K 1/12: Stationary parts of the magnetic circuit - C21D 1/773: under reduced pressure or vacuum - C21D 6/007: {containing Co} - C21D 6/008: {containing Si} - C21D 9/0068: {for particular articles not mentioned below} - C22C 38/002: {containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60} - C22C 38/02: containing silicon - C22C 38/10: containing cobalt - C22C 38/12: containing tungsten, tantalum, molybdenum, vanadium, or niobium - C22C 45/02: with iron as the major constituent - C23C 26/00: Coating not provided for in groups C23C2/00 - C23C24/00 - H02K 1/02: characterised by the magnetic material - H02K 1/04: characterised by the material used for insulating the magnetic circuit or parts thereof - H02K 15/02: of stator or rotor bodies - H02K 21/046: {with rotating permanent magnets and stationary field winding} - H02K 2213/03: Machines characterised by numerical values, ranges, mathematical expressions or similar information - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - C21D: MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass C23F17/00; unidirectional solidification of eutectic materials or unidirectional demixing of eutectoid materials C30B) - C22C: ALLOYS (treatment of alloys C21D, C22F) - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) ## Abstract A stator magnetic core and manufacturing process thereof and brushless motor comprising the stator magnetic core, wherein the stator magnetic core is made of iron-based amorphous material containing Co and V, and the composition of the iron-based amorphous material by weight percentage is: Co 0.8-1.4%, V 0.6-1.2%, B 2.7-3.3%, Si 6.5-8%, and Fe for the rest. A brushless DC motor, comprising a rotor spindle, a front end cover, a housing, a stator magnetic core and a rear end cover, wherein the stator magnetic core is assembled inside the housing, a stator coil is disposed inside the stator magnetic core, and the stator magnetic core and the stator core don't contact each other and an insulating layer is formed between them. The stator magnetic core in the present invention is made of iron-based amorphous material containing Co and V. Through addition of Co and V elements, the stator magnetic core refines crystalline grain and raises material toughness. It not only overcomes the previous problem of difficult machining and shaping but also raises the efficiency of the brushless DC motor containing this stator magnetic core. It is a breakthrough process. ## Claims ### Claim 1 A stator magnetic core, comprising: an iron-based amorphous material comprising Co and V, wherein the composition of the iron-based amorphous material by weight percentage is Co 0.8-1.4%, V 0.6-1.2%, B 2.7-3.3%, Si 6.5-8%, and Fe for the rest. ### Claim 2 (depends on 1) The stator magnetic core of claim 1, wherein the iron-based amorphous material by weight percentage is about Co 1%, V 0.8%, B 3.2%, Si 7.5%, and Fe 87.5%. ### Claim 3 (depends on 1) A manufacturing process of the stator magnetic core of claim 1, wherein a vacuum heat treatment process of the stator magnetic core comprises steps for: 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 with the furnace to a fourth temperature of 120° C.; and tapping off. ### Claim 4 (depends on 1) A manufacturing process of the stator magnetic core of claim 1, wherein a curing process after the heat treatment process and shaping of the stator magnetic core comprises steps for: raising to a first temperature of about 80-90° C., putting the stator magnetic core 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. ### Claim 5 (depends on 4) The manufacturing process of the stator magnetic core of claim 4, wherein the stator magnetic core is cut by a 3500 Ypm carborundum wheel under the protection of a cooling emulsion. ### Claim 6 (depends on 1) A brushless DC motor, comprising a rotor spindle, a front end cover, a housing, a rear end cover and the stator magnetic core of claim 1, wherein the stator magnetic core is assembled inside the housing; a stator coil being disposed inside the stator magnetic core; the stator magnetic core and the stator coil not contacting each other; and one or more insulating layers formed between them. ### Claim 7 (depends on 6) The brushless DC motor of claim 6, wherein the one or more insulating layers formed between them includes at least one insulating paper. ### Claim 8 (depends on 6) The brushless DC motor of claim 6, wherein the axes of a rotor spindle, the stator magnetic core and the stator coil coincide with each other. ### Claim 9 (depends on 6) The brushless DC motor of claim 6, wherein a lower part of the rotor spindle is disposed inside the housing. ### Claim 10 (depends on 6) The brushless DC motor of claim 6, wherein a portion of the lower part of the rotor spindle is disposed inside the housing in an inserted manner. ### Claim 11 (depends on 6) The brushless DC motor according to claim 6, wherein the stator magnetic core and one or more insulating layers are configured to reach an efficiency of about 87% at full load, ### Claim 12 (depends on 11) The brushless DC motor according to claim 11, wherein the rotor bearing is assembled at its bottom end and its top end is exposed. ### Claim 13 (depends on 11) The brushless DC motor according to claim 11, wherein a rotor bearing is disposed at one end of the rotor spindle. ### Claim 14 (depends on 6) The brushless DC motor according to claim 6, wherein the stator magnetic core and one or more insulating layers are configured to reach a speed of about a range from 28000-35000 rpm. ### Claim 15 (depends on 11) The brushless DC motor according to claim 11, wherein the stator magnetic core and one or more insulating layers are configured to reach a stable speed of about 30000. ### Claim 16 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. ### Claim 17 (depends on 16) The method of providing a DC brushless motor of claim 16, wherein the nano-epoxy curing agent is a V852-12A/B adhesive. ### Claim 18 (depends on 16) The method of providing a DC brushless motor of claim 16, further comprising steps for: machining the stator magnetic core by cutting by a 3500 Ypm carborundum wheel in a cooling emulsion. ### Claim 19 (depends on 16) The method of providing a DC brushless motor of claim 16, further comprising steps for: forming the stator magnetic core with an iron-based amorphous material containing Co and V, wherein the composition of the iron-based amorphous material by weight percentage is: Co 0.8-1.4%, V 0.6-1.2%, B 2.7-3.3%, Si 6.5-8%, and Fe. ### Claim 20 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. ### Claim 21 (depends on 20) The method of configuring a stator magnetic core of claim 20, wherein the one or more insulating layers is insulating paper. ### Claim 22 (depends on 20) The method of configuring a stator magnetic core of claim 20, wherein the stator magnetic core is made of iron-based amorphous material containing Co and V. ### Claim 23 (depends on 22) The method of configuring a stator magnetic core of claim 22, wherein the composition of the iron-based amorphous material by weight percentage is: Co 0.8-1.4%, V 0.6-1.2%, B 2.7-33%, Si 6.5-8%, and Fe. ### Claim 24 (depends on 20) The method of configuring a stator magnetic core of claim 20, further comprising steps for: curing an iron-based amorphous material mass with a nano-epoxy curing agent; shaping the iron-based amorphous material mass of the stator magnetic core workpiece; and machining the iron-based amorphous material mass in a cooling emulsion. ### Claim 25 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. ### Claim 26 (depends on 25) The computer implemented manufacturing process of the stator magnetic core of claim 25, further including steps for curing a stator magnetic core via one or more measurement sensors and one or more computers having process control software applications including computer-usable readable storage medium having computer-readable program code embodied therein for causing a computer system to perform methods for one or more programs of one or more process control manufacturing steps for providing steps for a curing process after the heat treatment process and steps for shaping of the stator magnetic core, including: raising to a first temperature of about 80-90° C. putting the stator magnetic core 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; and keeping the stator magnetic core in the 110° C. oven for two (2) hours. ### Claim 27 (depends on 25) The computer implemented manufacturing process of the stator magnetic core of claim 25, further including steps for shaping the stator magnetic core by cutting with a 3500 Ypm carborundum wheel under the protection of a cooling emulsion. ### Claim 28 A brushless DC motor, comprising a rotor spindle, a front end cover, a housing, a rear end cover and a stator magnetic core wherein the stator magnetic core is assembled inside a housing and wherein the stator magnetic core includes nanocrystalline materials with grain sizes of about 20 nanometers or less; a stator coil being disposed inside the stator magnetic core; the stator magnetic core and the stator coil not, contacting each other; and one or more insulating layers formed between them, a nanocrystalline microstructure portion formed within at least a portion of the stator magnetic core having a high saturation induction of at least about 1.5 Tesla (T), low core loss, and low saturation magnetostriction of an absolute value less than 4×10−6. ### Claim 29 (depends on 28) The brushless DC motor of claim 28, further comprising a stator magnetic core having amorphous alloys that form a nanocrystalline microstructure after curing by a nano-epoxy adhesive to form bulk amorphous magnetic components having lower operating, temperatures that magnetize and demagnetize more efficiently, wherein the stator magnetic core having one or more insulating layers formed between the stator magnetic core and stator magnetic coil includes at least one insulating paper layer. ### Claim 30 (depends on 29) The brushless DC motor of claim 29 wherein the stator magnetic core and one or more insulating layers are configured to reach a speed of about a range from 28000-35000 rpm. ### Claim 31 (depends on 30) The brushless DC motor of claim 30 wherein the stator magnetic core grains are oriented in the direction of the rolling process. ### Claim 32 (depends on 30) The brushless DC motor of claim 30 wherein the suitor magnetic core grains are comprised of a non-oriented optimized alloy. ### Claim 33 (depends on 30) The brushless DC motor of claim 30 wherein at least one of the stator magnetic core and one or more insulating layers are configured to have at least a portion of low core loss, bulk amorphous metal magnetic components. ### Claim 34 (depends on 33) The brushless DC motor of claim 33 wherein the low core loss, bulk amorphous metal magnetic components are cured by a curing agent of V852-12A/B nano-epoxy adhesive. ### Claim 35 (depends on 34) The brushless DC motor of claim 34 wherein the nano-epoxy adhesive has a viscosity of about less than 1000 cps and a thermal expansion coefficient of about 10 ppm. ### Claim 36 (depends on 34) The brushless DC motor of claim 34 wherein the nano-epoxy adhesive is applied according to a method selected from a group consisting of dipping, spraying, brushing, and electrostatic deposition. ### Claim 37 (depends on 34) The brushless DC motor of claim 34 wherein the nano-epoxy adhesive is selected from a group consisting of chemically activated, thermally activated, and activated by exposure to ultra-violet radiation. ### Claim 38 (depends on 33) The brushless DC motor of claim 33 wherein the low core loss, bulk amorphous metal magnetic components are bonded by impregnation with the nano-epoxy adhesive, diluted 1:5 by volume with acetone to reduce viscosity and enhance penetration in the grains. ### Claim 39 (depends on 33) The brushless DC motor of claim 33 wherein the stator magnetic core grains are configured to operate at a flux density of approximately about 1.3 Tesla (T) and a core-loss of less than or equal to 5.7 watts-per-kilogram of amorphous metal material. ### Claim 40 (depends on 39) The brushless DC motor of claim 39 wherein the brushless DC motor is configured to reach a speed of about 30000 rpm at a steady state. ### Claim 41 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. ### Claim 42 (depends on 41) The method of forming a stator magnetic core of claim 41, wherein at least one of the one or more insulating layers is insulating paper. ### Claim 43 (depends on 41) The method of forming a stator magnetic core of claim 41, further includes one or more steps wherein the stator magnetic core is made of iron-based amorphous material containing approximately by weight percentage, about Co 1% and V 0.8%. ### Claim 44 (depends on 41) The method of forming a stator magnetic core of claim 41, wherein the V852-12A/B nano-epoxy adhesive is replaced with a nano-epoxy adhesive compound having a thermal expansion and shrink coefficient of about 0 ppm. ### Claim 45 (depends on 44) The method of forming a stator magnetic core of claim 44, wherein the nano-epoxy adhesive is replaced with a compound having a viscosity of about less than 1000 cps and a thermal expansion coefficient of about 0 ppm. ### Claim 46 (depends on 44, 45) The method of forming a stator magnetic core of claim 44 or 45, wherein the low core loss, bulk amorphous metal magnetic components are bonded by impregnation with the nano-epoxy adhesive diluted by 1:5 by volume with acetone to enhance penetration in the grains.