US 8,505,351 B2Granted

Product and method for manufacturing a three dimensional core mass and related inventions

OwnerFrederick William Klattinventor

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Abstract

A three dimensional shape core mass is manufactured by machining a ribbon or tape of any material with various slots, channels, or holes of any shape before the ribbon or tape is spooled or layered onto a layering template or spooler. The machining is adjusted so the slots, channels, or holes of any shape extend in a radial or stacked direction perpendicular to the axis of spooling rotation or the plane of layering but with any curve or straight line and with any stacked length. For example, core masses that are manufactured as described are suitable as magnetic cores for high frequency rotating or linear transformers or for rotors and for stators of rotating or linear electric machines when an appropriate magnetic material is used, such as magnetic metal or amorphous metal ribbon or tape.

Claims18

Dependent claims

A method for manufacturing a three dimensional core mass of at least one ribbon of metal comprising the steps of:

modifying in a two-dimensional plane said ribbon to form a slot, channel or hole in said ribbon;
and
wrapping said modified ribbon onto at least one spooler with at least one wrap of said ribbon;
wherein said modifying is activated by detection of at least one event from a slot template of pre-calibrated events that follows the movement of said spooler;
wherein said pre-calibrated events are selected from a group consisting of angle, distance, speed, and time, and said detection is selected from a group consisting of light, magnetism, and electricity;
wherein said spooler serves as a shaping template for said three dimensional core mass;
wherein said three dimensional core mass is built up onto said spooler with at least one wrap of said modified ribbon at a time;
wherein said modified ribbon extends per wrap in a radial direction from a rotation axis of said spooler.

5 more elements

Dependencies are inferred from the claim text.