Method for manufacturing a soft magnetic metal electromagnetic component
AssigneeLight Engineering, Inc.
InventorsThomas J. Berwald, Kendall S. Page, Andrew D. Hirzel
Life of this patent
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Abstract
An electromagnetic component is formed from a pre-form comprising layers of soft magnetic metal ribbon. Adhesive is applied to permeate the pre-form and is then cured. The bonded pre-form is placed within a milling assembly that supports and constrains the ribbon layers during a milling operation used to process the pre-form into an electromagnetic component shape. Optionally, the shape is thermally processed. The resulting electromechanical component has attractive soft magnetic properties, including low core loss, that render it useful as a component in electric motors and generators and static inductive devices operable at high excitation frequencies.
Claims33
A method for manufacturing a soft magnetic metal electromagnetic component comprising the steps of:
- forming soft magnetic metal ribbon having edges into a pre-form comprising a plurality of stacked or wound layers of the ribbon, the edges being in registry and the ribbon consisting essentially of a material selected from the group consisting of amorphous and nanocrystalline metals and optimized Fe-based alloy;
- containing the pre-form within a containment means that supports the pre-form on all sides;
- milling the pre-form contained within the containment means into a electromagnetic component shape;
- and
- thermally processing the electromagnetic component shape into an electromagnetic component at a thermal processing temperature,
- and wherein the containing step comprises the steps of applying an adhesive to the pre-form;
- and curing the adhesive to form a bonded pre-form, the curing being carried out at a heat curing temperature less than the thermal processing temperature.
A method for manufacturing a soft magnetic metal electromagnetic component comprising the steps of:
- forming soft magnetic metal ribbon having edges into a pre-form comprising a plurality of layers of the ribbon wound into a toroid having a shape of a right circular cylinder having a toroid axis, an inner side surface, an outer side surface, a top, and a bottom, the edges being in registry;
- containing the pre-form within a milling assembly, comprising placing an inner ring of the milling assembly circumferentially about at least a portion of the inner side surface;
- applying an adhesive to the pre-form within the milling assembly;
- curing the adhesive to form a bonded pre-form;
- milling the bonded pre-form contained within the milling assembly into an electromagnetic component shape;
- and
- thermally processing the bonded pre-form.
A method for manufacturing a soft magnetic metal electromagnetic component comprising the steps of:
- winding soft magnetic metal ribbon about a winding axis into a toroid, the toroid having an inner side, an outer side, a top and a bottom;
- placing an inner ring on the inner side;
- placing an inner containment hat on the top and inner side;
- placing an outer containment hat on the top and outer side;
- placing a retainer around the outer containment hat;
- applying adhesive to the toroid;
- curing the adhesive;
- milling the toroid while disposed within the inner and outer containment hats into an electromagnetic component shape;
- applying a magnetic field to the electromagnetic component shape;
- and
- thermally processing the electromagnetic component shape into an electromagnetic component.
Dependencies are inferred from the claim text.