Method of making a magnetic core

Abstract

A method of constructing a jointed magnetic core from amorphous metal, which includes winding a closed core loop having a plurality of nested lamination turns disposed about a core opening or window, and positioning the closed core loop on a support surface with the winding axis horizontally disposed, to allow the inherent flexibility of amorphous metal to collapse the loop opening and create a concave loop in the unsupported portion of the closed core loop. The method further includes the step of lifting a plurality of lamination turns from the concave loop portion, to provide a clearance between the raised lamination turns and the remaining lamination turns in the concave loop to facilitate cutting the lamination turns. A cutting device, which may be a laser or a mechanical cutter, cuts one or more of the raised lamination turns. The method then repeats the steps of raising and cutting lamination turns, with the core loop or the cutting device being indexed to stagger the cuts and create a predetermined stepped-lap joint pattern when the cut lamination turns are subsequently assembled into a closed core loop.

Dependencies are inferred from the claim text.