Source: https://patents.google.com/patent/US20130292081A1/en
Timestamp: 2018-12-10 20:00:45
Document Index: 222462471

Matched Legal Cases: ['§119', '§1', '§1', 'art 1268', 'art 1268', 'art 1318', 'art 1318', 'art 1358']

US20130292081A1 - System and method for making a structured magnetic material with integrated particle insulation - Google Patents
System and method for making a structured magnetic material with integrated particle insulation Download PDF
US20130292081A1
US20130292081A1 US13836615 US201313836615A US2013292081A1 US 20130292081 A1 US20130292081 A1 US 20130292081A1 US 13836615 US13836615 US 13836615 US 201313836615 A US201313836615 A US 201313836615A US 2013292081 A1 US2013292081 A1 US 2013292081A1
US13836615
US10022789B2 (en )
A system for forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material. The systems has a heating device; a deposition device; a support configured to support the soft magnetic bulk material of the predetermined shape; and a mask configured as a negative of at least a portion of the predetermined shape. The heating device heats the magnetic material to form particles having a softened state and wherein the deposition device deposits successive layers of particles of the magnetic material in the softened state on the support with the mask located between the deposition device and the support. The mask is indexed to a position relative to the support upon deposition of the successive layers. The mask selectively blocks the successive layers of particles of the magnetic material in the softened state from being deposited on the support forming the soft magnetic bulk material of a predetermined shape on the support.
This application is a continuation-in-part of application of U.S. patent application Ser. No. 13/507,448 filed on Jun. 29, 2012 and which claims the benefit of and priority to U.S. Provisional Application Ser. No. 61/571,551 filed on Jun. 30, 2011, and under 35 U.S.C. §§119, 120, 363, 365, and 37 C.F.R. §1.55 and §1.78, both of which applications are incorporated herein by this reference.
Soft magnetic composites (SMC) include powder particles with an insulation layer on the surface. See, e.g., Jansson, P., Advances in Soft Magnetic Composites Based on Iron Powder, Soft Magnetic Materials, '98, Paper No. 7, Barcelona, Spain, April 1998, and Uozumi, G. et al., Properties of Soft Magnetic Composite With Evaporated MgO Insulation Coating for Low Iron Loss, Materials Science Forum, Vols. 534-536, pp. 1361-1364, 2007, both incorporated by reference herein. In theory, SMC materials may offer advantages for construction of motor stator cores when compared with steel laminations due to their isotropic nature and suitability for fabrication of complex components by a net-shape powder metallurgy production route.
Electric motors built with powder metal stators designed to take full advantage of the properties of the SMC material have recently been described by several authors. See, e.g., Jack, A. G., Mecrow, B. C., and Maddison, C. P., Combined Radial and Axial Permanent Magnet Motors Using Soft Magnetic Composites, Ninth International Conference on Electrical Machines and Drives, Conference Publication No. 468, 1999, Jack. A. G. et al., Permanent-Magnet Machines with Powdered Iron Cores and Prepressed Windings, IEEE Transactions on Industry Applications, Vol. 36, No. 4, pp. 1077-1084, July/August 2000, Hur, J. et al., Development of High-Efficiency 42V Cooling Fan Motor for Hybrid Electric Vehicle Applications, IEEE Vehicle Power an Propulsion Conference, Windsor, U.K., September 2006, and Cvetkovski, G., and Petkovska. L., Performance Improvement of PM Synchronous Motor by Using Soft Magnetic Composite Material, IEEE Transactions on Magnetics, Vol. 44, No. 11, pp. 3812-3815, November 2008, all incorporated by reference herein, reporting significant performance advantages. While these motor prototyping efforts demonstrated the potential of isotropic materials, the complexity and cost of the production of a high performance SMC material remains a major limiting factor for a broader deployment of the SMC technology.
For example, in order to produce a high-density SMC material based on iron powder with MgO insulation coating, the following steps may be required: 1) iron powder is produced, typically using a water atomization process, 2) an oxide layer is formed on the surface of the iron particles, 3) Mg powder is added, 4) the mixture is heated to 650° C. in vacuum, 5) the resulting Mg evaporated powder with silicon resin and glass binder is compacted at 600 to 1,200 MPa to form a component; vibration may be applied as part of the compaction process, and 6) the component is annealed to relieve stress at 600° C. See, e.g., Uozumi. G. et al., Properties of Soft Magnetic Composite with Evaporated MgO Insulation Coating for Low Iron Loss, Materials Science Forum, Vols. 534-536, pp. 1361-1364, 2007, incorporated by reference herein.
The source of insulating material may comprise a reactive chemical source and the deposition device deposits the particles of the magnetic material in the softened or molten state on the support in a deposition path such that insulating boundaries may be formed on the magnetic material by the coating device from a chemical reaction of the reactive chemical source in the deposition path. The source of insulating material may comprise a reactive chemical source and insulating boundaries may be formed on the magnetic material by the coating device from a chemical reaction of the reactive chemical source after the deposition device deposits the particles of the magnetic material in the softened or molten state on to the support. The softened state may be at a temperature above the melting point of the magnetic material. The source of insulating material may comprise a reactive chemical source and the insulating boundaries may be foil red from a chemical reaction of the reactive chemical source at the surface of the particles. The deposition device may comprise a uniform droplet spray deposition device. The source of insulating material may comprise a reactive chemical source and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source in a reactive atmosphere. The source of insulating material may comprise a reactive chemical source and an agent and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source in a reactive atmosphere stimulated by a co-spraying of the agent. The insulating boundaries may be formed from co-spraying of the insulating material. The insulating boundaries may be formed from a chemical reaction and a coating from the source of insulating material. The softened state may be at a temperature below the melting point of the magnetic material. The system may include a coating device which coats the magnetic material with the insulating material. The particles may comprise the magnetic material coated with the insulating material. The particles may comprise coated particles of magnetic material coated with the insulating material and the coated particles are heated by the heating device. The system may include a coating device which coats the magnetic material with the insulating material from the source and the deposition device deposits the particles simultaneously while the coating device coats the magnetic material with the insulating material. The system may include a coating device which may coat the magnetic material with the insulating material after the deposition device deposits the particles.
The source of insulating material may comprise a reactive chemical source and the coating device may coat the magnetic material with the insulating material to form insulating boundaries from a chemical reaction of the reactive chemical source at the surface of the particles. The source of insulating material may comprise a reactive chemical source and the coating device may coat the magnetic material with the insulating material to form insulating boundaries formed from a chemical reaction of the reactive chemical source in a reactive atmosphere. The source of insulating material may comprise a reactive chemical source and an agent and the coating device may coat the magnetic material with the insulating material from the source to form insulating boundaries formed from a chemical reaction of the reactive chemical source in a reactive atmosphere stimulated by a co-spraying of the agent. The coating device may coat the magnetic material with the insulating material from the source to form insulating boundaries formed from a co-spraying of the insulating material. The coating device may coat the magnetic material with the insulating material from the source to form insulating boundaries formed from a chemical reaction and a coating from the source of insulating material. The soft magnetic bulk material may include domains formed from the magnetic material with insulating boundaries. The softened state may be at a temperature below the melting point of the magnetic material. The deposition device may deposit the particles simultaneously while the coating device coats the magnetic material with the insulating material. The coating device may coat the magnetic material with the insulating material after the deposition device deposits the particles.
In accordance with one aspect of the disclosed embodiment, a method of forming a bulk material with insulated boundaries is provided. The method includes providing a metal material, providing a source of insulating material, providing a support configured to support the bulk material, heating the metal material to a softened state, and depositing particles of the metal material in the softened or molten state on the support to form the bulk material having domains formed from the metal material with insulating boundaries.
In accordance with another aspect of the disclosed embodiment, an electrical device coupled to a power source is provided. The electrical device includes a soft magnetic core and a winding coupled to the soft magnetic core and surrounding a portion of the soft magnetic core, the winding coupled to the power source. The soft magnetic core includes a plurality of domains of magnetic material, each of the domains of the plurality of domains substantially separated by a layer of high resistivity insulating material. The plurality of domains includes successive domains of magnetic material progressing through the soft magnetic core. Substantially all of the successive domains in the second portion each including a first surface and a second surface, the first surface comprising a substantially convex surface and the second surface comprising one or ore substantially concave surfaces.
In another exemplary embodiment, a system for forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material is provided. The systems has a heating device; a deposition device; a support configured to support the soft magnetic bulk material of the predetermined shape; and a mask configured as a negative of at least a portion of the predetermined shape. The heating device heats the magnetic material to form particles having a softened state and wherein the deposition device deposits successive layers of particles of the magnetic material in the softened state on the support with the mask located between the deposition device and the support. The mask is indexed to a position relative to the support upon deposition of the successive layers. The mask selectively blocks the successive layers of particles of the magnetic material in the softened state from being deposited on the support forming the soft magnetic bulk material of a predetermined shape on the support.
In accordance with another exemplary method, a method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material is provided. The method comprises providing a heating device; providing a deposition device; providing a support configured to support the soft magnetic bulk material of the predetermined shape; providing a mask configured as a negative of at least a portion of the predetermined shape; heat the magnetic material with the heating device to form particles having a softened state; locating the mask between the deposition device and the support; depositing successive layers of particles of the magnetic material in the softened state with the deposition device on the support; and indexing a position relative to the support the mask upon deposition of the successive layers. The mask selectively blocks the successive layers of particles of the magnetic material in the softened state from being deposited on the support forming the soft magnetic bulk material of a predetermined shape on the support.
In accordance with another exemplary method, a method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a non-magnetic material is provided. The method comprises providing a reservoir adapted to contain the soft magnetic bulk material of the predetermined shape; providing a heat source; and heating the magnetic material and the non-magnetic material in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of a predetermined shape. The soft magnetic bulk material of a predetermined shape has domains formed from the magnetic material with insulating boundaries formed from the reaction.
FIG. 35 is a schematic top-view of an inductor incorporating the structured material of the disclosed embodiment;
FIG. 37 is a schematic section view of a deposition system;
FIG. 38 is a view of a stator;
FIG. 39 is a view of a mask;
FIG. 40 is a view of a mask;
FIG. 41 is a sectional view of a material;
FIG. 42 is a sectional view of a material;
FIG. 43 is a schematic sectional view of a deposition system;
FIG. 44 is a schematic sectional view of a deposition system; and
FIG. 45 is a view of a mold.
System 10′″, FIG. 6, where like parts include like numbers, may also include spray subsystem 60 which includes at least one port, e.g., port 62 and/or port 63, which is configured to introduce agent 64 into spray chamber 18. Spray subsystem 60 creates spray 66 and/or spray 67 of spray agent 64 which coats droplets 16 having insulation layers thereon, e.g., insulation layers 30, FIG. 1, with agent 64, FIG. 3, while droplets 16 are in flight toward surface 20. Agent 64 preferably may stimulate a chemical reaction that forms insulation layer 30 and/or coat the particle to form insulation layer 30; or a combination thereof, which may take place either simultaneously or sequentially. In a similar manner, system 10′, FIG. 3, and system 10″. FIG. 4, may also introduce an agent at in-flight droplets 16. Caption 28, FIG. 1, shows one example of agent 64 (in phantom) coating droplets 16 with insulating coating 30. Agent 64 provides material 32 with additional insulating capabilities. Agent 64 preferably may stimulate the chemical reaction that forms insulation layer 30; may coat the particle to form insulation layer 30; or a combination thereof which may take place either simultaneously or sequentially.
System 10, FIGS. 1, 2, and 6, may include pressure sensor 102 inside chamber 46, FIG. 1 or chamber 252, FIG. 2. System 10, FIGS. 1, 2, and 6, may also include pressure sensor 104, FIG. 2 inside spray chamber 18 and/or differential pressure sensor 106, FIGS. 1, 2, and 6 between crucible 14 and spray chamber 18 and/or differential pressure sensor 106. FIG. 2, between chamber 252 and spray chamber 18. The information about the pressure difference provided by sensors 102 and 104 or 106 may be utilized to control the supply of inert gas 47, FIGS. 1 and 6, to crucible 14 and the supply of gas 26 into the spray chamber 18 or the supply of gas 262, 264, FIG. 2, to chamber 252. The difference in the pressures may serve as a way of controlling the ejection rate of molten alloy 44 through orifice 20. In one design, controllable valve 108, FIG. 6, coupled to port 45 may be utilized to control the flow of inert gas into chamber 46. Similarly, control valve 266 may be used to control the flow of gases 262, 264 into chamber 252. Controllable valve 110. FIGS. 1, 2, and 6, coupled to port 24 may be utilized to control the flow of gas 26 into spray chamber 18. A flow meter (not shown) may also be coupled to port 24 to measure the flow rate of gas 26 into spray chamber 18.
System 10, FIGS. 1, 2, and 6, may also include a controller (not shown) that may utilize the measurements from the sensors 102, 104 and/or 106 and the information from a flow meter coupled to port 24 to adjust the controllable valves 108, 110 or 266 to maintain the desired pressure differential between chamber 46 and spray chamber 18 or chamber 252 and spray chamber 18 and the desired flow of gas 26 into spray chamber 18. The controller may utilize the measurements from temperature sensor 48 in crucible 14 to adjust operation of heater 42 to achieve/maintain the desired temperature of molten alloy 44. The controller may also control the frequency (and possibly amplitude) of the force produced by actuator 50. FIG. 1, of the vibration transmitter 51 in the crucible 14.
Hybrid-field geometries of electric motors may be developed using material 32 with domains 34 with insulated boundaries 36. Material 32 may eliminate design constraints associated with anisotropic laminated cores of conventional motors. The system and method of making material 32 of one or more embodiments of this invention may allow for the motor cores to accommodate built-in cooling passages and togging reduction measures. Efficient cooling is essential to increase current density in the windings for high motor output, e.g., in electric vehicles. Cogging reduction measures are critical for low vibration in precision machines, including substrate-handling and medical robots.
System 10 and method of making material 32 of one or more embodiments of this invention may utilize the most recent developments in the area of uniform-droplet spray (UDS) deposition techniques. The UDS process is a way of rapid solidification processing that exploits controlled capillary atomization of molten jet into mono-size uniform droplets. See, e.g., Chun, J.-H., and Passow, C H., Production of Charged Uniformly Sized Metal Droplets, U.S. Pat. No. 5,266,098, 1992, and Roy, S., and Ando T., Nucleation Kinetics and Microstructure Evolution of Traveling ASTM F75 Droplets, Advanced Engineering Materials, Vol. 12, No. 9, pp. 912-919, September 2010, both incorporated by reference herein. The UDS process can construct objects droplet by droplet as the uniform molten metal droplets are densely deposited on a substrate and rapidly solidified to consolidate into compact and strong deposits.
System 10 and method of making material 32 may use the fundamental elements of the conventional UDS deposition processes to create droplets 16. FIGS. 1-4, 6 and 7, which have a uniform diameter. Droplet spray subsystem 12, FIG. 1, may use a conventional UDS process that is combined with simultaneous formation of insulation layer 30 on the surface of the droplets 16 during their flight to produce dense material 32 with a microstructure characterized by small domains of substantially homogeneous material with insulation boundaries that limit electrical conductivity between neighboring domains. The introduction of a gas 26, e.g., reactive atmosphere or similar type gas, for simultaneous formation of the insulation layer on the surface of the droplets adds the features of simultaneously controlling the structure of the substantially homogeneous material within the individual domains, the formation of the layer on the surface of the particles (which limits electric conductivity between neighboring domains in the resulting material), and breakup of the layer upon deposition to provide adequate electric insulation while facilitating sufficient bonding between individual domains.
FIG. 10A shows one example of material 332 that includes domains 334 with insulated boundaries 336 there between created using one embodiment of system 310 discussed above with reference to one or more of FIGS. 8 and 9. Insulated boundaries 336 are formed from insulation layer 330, FIG. 9, on droplets 316. In one example, material 332, FIG. 10A, includes boundaries 336 between neighboring domains 334 which are virtually perfectly formed as shown. In other examples, material 332, FIG. 10B, may include boundaries 336′ between neighboring domains 334 with discontinuities as shown. Material 332. FIGS. 9, 10A and 10B, reduces eddy current losses, and discontinuities boundaries 336 between neighboring domains 334 improve the mechanical properties of material 332. The result is that material 332 may preserve a high permeability, a low coercivity and a high saturation induction of the alloy. Boundaries 336 limit electrical conductivity between neighboring domains 334. Material 332 provides a superior magnetic path due to its permeability, coercivity and saturation characteristics. The limited electrical conductivity of material 332 minimizes eddy current losses associated with rapid changes of the magnetic field as a motor rotates. System 310 and the method thereof may be a single step, fully automated process which saves time and money and produces virtually no waste.
FIG. 12 shows one example of system 310, FIG. 8, wherein spray 506, 508, FIG. 12, is sprayed on substrate 512 to form an insulation layer thereon before droplets 316 are deposited, indicated at 525. Thereafter, spray 506, 508 may be directed at subsequent layers of deposited droplets 316 on substrate 512 to insulation layer 330 indicated at 527, 529. The result is material 332 is created which includes domains 334 with insulated boundaries 336, e.g., as discussed above with reference to FIGS. 10A-10B.
System 310′, FIG. 13, where like parts have like numbers, preferably includes chamber 318 with separation barrier 524 that creates sub-chambers 526 and 528. Separation barrier 524 preferably includes opening 529 configured to allow droplets 316, e.g. droplets of molten alloy 344 or similar type material, to flow from sub-chamber 526 to sub-chamber 528. Sub-chamber 526 may include gas inlet 528 and gas exhaust 530 configured to maintain a predetermined pressure and gas mixture in sub-chamber 226, e.g., a substantially neutral gas mixture. Sub-chamber 528 may include gas inlet 530 and gas exhaust 532 configured to maintain predetermined pressure and gas mixture in sub-chamber 528, e.g., as substantially reactive gas mixture.
where vs is speed of substrate, f is frequency of deposition, i.e., frequency of ejection of droplets 316 from crucible 314, and ds is diameter of splat formed by a droplet after landing on the surface of the substrate.
d s = v l × 1 f ( 2 ) b = d s  Cos  ( 30   deg ) ( 3 ) m = d s 2 ( 4 ) n = d s 2  Tan  ( 30   deg ) ( 5 )
In operation, the voltage applied to positive are wire 554 and negative arc wire 556 creates arc 570 which causes alloy 558 to form molten alloy droplets 316, which are directed towards surface 320 inside chamber 318. In one example, voltages between about 18 and 48 volts and currents between about 15 to 400 amperes may be applied to positive arc wire 554 and negative arc wire 556 to provide a continuous wire arc spray process of droplets 316. The deposited molten droplets 316 may react on the surface with surrounding gas 568, also shown in FIGS. 19-20, to develop a non-conductive surface layer on deposited droplets 316. This layer may serve to suppress eddy current losses in material 332, FIGS. 10A-10B, having domains with insulated boundaries. For example, surrounding gas 568 may be atmospheric air. In this case, oxide layers may form on iron droplets 316. These oxide layers may include several chemical species, including, e.g., FeO, Fe2O3, Fe3O4, and the like. Among these species, FeO and Fe2O3 may have resistivities eight to nine orders of magnitude higher than pure iron. In contrast, Fe3O4 resistivity may be two to three orders of magnitude higher than iron. Other reactive gases may also be used to produce other high resistivity chemical species on the surface. Simultaneously or separately, an insulating agent may be co-sprayed, e.g., as discussed above with reference to one or more of FIGS. 8-9 and 11-15 during the metal spray process to promote higher resistivity, e.g., a lacquer or enamel. The co-spray may promote or catalyze a surface reaction.
In another example, system 310′, FIG. 19, where like parts have been given like numbers, includes droplet spray subsystem 312″. Subsystem 312″ includes wire arc deposition subsystem 550′ that creates molten alloy droplets 316 and directs molten alloy droplets 316 towards surface 320. In this example, droplet spray subsystem 312″ does not include chamber 552, FIG. 18, and chamber 318. Instead, nozzle 560, FIG. 19, is configured to introduce one or more gases 562, 564 to create gas 568 in the area proximate positive arc wire 554 and negative arc wire 556. Gas 568 propels droplets 316 toward surface 514. Spray 506 and/or spray 508 of agent 504 is then directed onto or above surface 514 of substrate 512, having deposited droplets 316 thereon, e.g., using spray nozzle 513, similar as discussed above. In this design, a shroud, e.g., shroud 523, may be surround spray 506 and/or spray 508 of agent 504 and droplets 316 which are deposited on substrate 512.
System 310″, FIG. 20, where like parts have been given like numbers, is similar to system 310″, FIG. 19, except wire arc spray subsystem 550″ includes a plurality of positive arc wire 554, negative arc wires 556 and nozzles 560 which may be used simultaneously to achieve higher spray deposition rates of molten alloy droplets 316. Wire arcs 254, 256, and similar deposition devices, may be provided in different directions to form the material having domains of insulated boundaries. Spray 506 and/or spray 508 of agent 504 is directed onto or above surface 514 of substrate 512, similar as discussed above with reference to FIG. 19. Here, a shroud, e.g., shroud 523, may surround spray 506 and/or spray 508 of agent 504 and droplets 316 deposited on substrate 512.
Thus far, system 10 and system 310 and the methods thereof forms an insulation layer on in-flight or deposited droplets to form the material having domains with insulated boundaries. In another disclosed embodiment, system 610, FIG. 21, and the method thereof, forms the material having domains with insulated boundaries by injecting a metal powder comprised of metal particles coated with an insulation material into a chamber to partially melt the insulation layer. The conditioned particles are then directed at a stage to form the material having domains with insulated boundaries. System 610 includes combustion chamber 612 and gas inlet 614 which injects gas 616 into chamber 612. Fuel inlet 618 injects fuel 620 into chamber 612. Fuel 620 may be a fuel such as kerosene, natural gas, butane, propane, and the like. Gas 616 may be pure oxygen, an air mixture, or similar type gas. The result is a flammable mixture inside chamber 612. Igniter 622 is configured to ignite the flammable mixture of fuel and gas to create a predetermined temperature and pressure in combustion chamber 612. Igniter 622 may be a spark plug or similar type device. The resulting combustion increases the temperature and pressure within combustion chamber 612 and the combustion products are propelled out of chamber 612 via outlet 624. Once the combustion process achieves a stead state, i.e. when the temperature and pressure in combustion chamber stabilizes, e.g., to a temperature of about 1500K and a pressure of about 1 MPa, metal powder 624 is injected into combustion chamber 612 via inlet 626. Metal powder 624 is preferably comprised of metal particles 626 coated with an insulating material. As shown by caption 630, particles 626 of metal powder 624 include inner core 632 made of a soft magnetic material, such as iron or similar type material, and outer layer 634 made of the electrically insulating material preferably comprised of ceramic-based materials, such as alumina, magnesia, zirconia, and the like, which results in outer layer 634 having a high melting temperature. In one example, metal powder 624 comprised of metal particles 626 having inner core 632 coated with insulating material 634 may be produced by mechanical (mechanofusion) or chemical processes (soft gel). Alternatively, insulation layer 634 can be based on ferrite-type materials which can improve magnetic properties due to their high reactive permeability by preventing or limiting the heat temperature, e.g., such as annealing.
FIG. 22A shows an example of material 48 that includes domains 650 with insulated boundaries 652 therebetween. In one example, material 648 includes boundaries 652 between neighboring domains 650 which are virtually perfectly formed as shown. In other examples, material 648 FIG. 22B, may include boundaries 652′ between neighboring domains 50 with discontinuities as shown. Material 648, FIGS. 22A and 22B, reduces eddy current losses and discontinuities boundaries 652 between neighboring domains 650 improve the mechanical properties of material 648. The result is that material 648 preserves a high permeability, a low coercivity and a high saturation induction of the alloy. Boundaries 652 limit electrical conductivity between neighboring domains 650. Material 648 preferably provides a superior magnetic path due to its permeability, coercivity and saturation characteristics. The limited electrical conductivity of material 648 minimizes eddy current losses associated with rapid changes of the magnetic field as a motor rotates. System 610 and the method thereof may be a single step, fully automated process which saves time and money and produces virtually no waste.
Referring now to FIG. 37, there is shown another aspect of the disclosed embodiment with respect to system 1100. System 1100 may be provided for forming a soft magnetic bulk material of a predetermined shape from a magnetic material 1112 and a source of insulating material. Here, the magnetic material and source of insulating material and deposition thereof may be as disclosed with respect to deposition system 10 and the disclosed variants, system 310 and disclosed variants, 610 and disclosed variants, or any suitable deposition system as disclosed. For example, system 1100 may have a source of magnetic material 1112 where the material is in powder form, solid form or otherwise and where the material is deposited by deposition device 1114 that may be as previously disclosed and as disclosed and may be any suitable deposition source such as a molten source of molten or softened magnetic material by wire arc, HVOF, HVAF, plasma spray, flame spray or any suitable source. The source of insulating material may be where the magnetic particles are pre coated. Alternately, the source of insulating material may be from a chemical reaction within enclosure 1116 as disclosed, for example, where a reactive gas may be introduced into enclosure 116 and where the reactive gas forms insulating material on the surface of the particles from deposition source 1114 as disclosed. By way of example, the reactive gas may be oxygen or air where an oxide is grown on the surface of particles 1118 being deposited while in flight. Further, the deposited magnetic material may be subsequently coated with insulating material as disclosed. Further, the deposited magnetic material may form an insulating layer by a chemical reaction, for example, a thermite reaction as will be covered in greater detail below. System 1100 has heating device 1120, deposition device 1114 and support 1122 configured to support the soft magnetic bulk material of the predetermined shape 1110. Masks 1124, 1126 are configured as a negative of at least a portion of the predetermined shape 1110. The heating device 1120 heats the magnetic material to form particles having a softened state 1118 and wherein the deposition device 1114 deposits successive layers 1128 . . . 1130 of particles of the magnetic material in the softened state 1118 on the support 1122 with the masks 1124, 1126 located between the deposition device 1114 and the support 1122. Here, the mask subsystem is indexed in the direction of arrow 1132 to a position 1134 relative to the support 1122 upon deposition of the successive layers 1128 . . . 1130. The mask selectively blocks the successive layers of particles of the magnetic material in the softened state from 1118 being deposited on the support 1122 forming the soft magnetic bulk material of a predetermined shape 1110 on the support 1122. First 1124 and second masks 1126 are shown coupled to each other such that when they are indexed, they block deposition of the magnetic material on portions 1140, 1142 of the support 1122 that selectively are not to be deposited on. The mask may be made from any suitable metal, glass, ceramic, fiberglass, composite or any suitable material that will not melt and retains its shape during deposition. Further, the deposited metal 1118 may in one aspect not stick to mask 1124, 1126. Support 1122 and mask 1124, 1126 may be moveable in a plane 1146 such that material may be selectively deposited on any portion of material 1110. Further one or more portions of the mask may be moveable relative to the other. For example, when the masks are indexed, either mask 1126 or mask 1124 may be moveable relative to the other. Referring also to FIGS. 38, 29 and 40, by way of example, the soft magnetic bulk material of a predetermined shape 1110 on the support 1122 may be a stator 1110 and where the masks may be a negative 1126 of the inner shape of the stator and a negative 1124 of the outer shape of the stator as seen in FIGS. 39 and 40 respectively. If the stator is to have skewed teeth, the inner mask 1126 may be rotated 1150 slightly with each successive index where the first mask 1126 is moveable relative to the second mask 1124. In the embodiment shown, the mask is shown moveable relative to the support. In alternate aspects, the support may be shown moveable relative to the mask. In the embodiment shown, the mask and support is shown moveable relative to the deposition device. Alternately, the deposition device may be moveable relative to the support and mask. Shape 1110 is shown with uniform cross section. Alternately, any non uniform cross section may be provided where different masks are provided as negatives that reflect the non uniform cross section of the soft magnetic bulk material of a predetermined shape with a non uniform cross section. Here, the mask 1124, 1126 may be more than one mask having different shapes corresponding to different cross sections of the soft magnetic bulk material of a predetermined shape 1110 with a non uniform cross section at different index positions 1134.
Referring now to FIG. 41, there is shown a cross section of a bulk material 1200. Here, the bulk material may be in powdered or particulate form. Bulk material 1200 has iron particles 1210 with the iron particles having a thin layer 1212 of iron oxide on the surface of the iron particles 1210. Between the iron oxide coated iron particles are also particles of aluminum 1214. The iron oxide may occur naturally from exposure or purposefully, for example, by acid bath or otherwise. Referring also to FIG. 42, heat 1220 may be added to the bulk material, for example, as will be described, or from any suitable heat source such as the iron itself, a flame, magnesium flame, torch, laser, microwave or otherwise. Upon heating the material, a thermite reaction may be started whereby the following reaction may take place with respect to the iron oxide coating and the aluminum:
Fe2O3+2Al=>Al2O3+2Fe
The reaction results in a structure 1200′ as seen in FIG. 42 whereby iron particles 1210 reside in a composite structure and surrounded by aluminum oxide 1222 forming a soft magnetic material having domains 1210 of magnetic material surrounded by insulating material 1222. In alternate aspects, other materials, for example, other than iron or other than iron oxide or other than aluminum may be provided. By way of example, the powder may be Fe, FeSi, FeSiAl, FeAl or any suitable material. For example, the iron particles may be pre coated with a different material. As will be described, the principle reaction may be done as a chain reaction with the bulk material, for example, in a mold. Alternately, the reaction may be controlled locally. For example, a method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material 1210 and a non-magnetic material 1214 may be provided by providing a reservoir adapted to contain the soft magnetic bulk material of the predetermined shape as will be described. Here, a heat source 1220 may be provided for heating the magnetic material and the non-magnetic material in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of a predetermined shape. Here, the soft magnetic bulk material has domains 1210 formed from the magnetic material with insulating boundaries 1222 formed from the reaction.
FIG. 43 shows an example of an apparatus 1250 that uses an additive principle to form a soft magnetic bulk material that has domains formed from the magnetic material with insulating boundaries formed from the thermite reaction as described. System 1250 may be an adaptation of a selective laser sintering system as will be described. System 1250 has powder delivery piston 1260, powder delivery reservoir 1262, roller or pusher 1264, fabrication piston 1270, object being fabricated 1268, fabrication powder bed 1266, heat source and alternate powder source 1276. Scanning platform 1280 selectively positions heat source 1274 and powder source 1276 to direct heat and material to a portion of fabrication powder bed 1266 to turn the bulk material from powder form to solid form. In practice, iron particles with iron oxide coating are provided within reservoir 1262. In the embodiment shown, support or piston 1270 may be heated, for example, to facilitate the reaction or stress relieve part 1268. To build successive layers of object 1268, fabrication piston 1270 is indexed down an increment and powder delivery piston 1260 is indexed up an increment. Roller or pusher 1264 pushes a layer of material from powder reservoir 1262 to replenish the fabrication powder bed 1266 with a fresh layer of powder. Scanner 1280 selectively moves heat source 1274 and alternate powder source 1276 to solidify a portion of the fresh bed of powder to build up the next layer of the object being fabricated 1268. The process is repeated until the object being fabricated 1268 is complete. In the embodiment shown, the powder 1262 may be iron oxide coated iron particles, the heat source 1274 may be a switchable laser and the alternative powder source 1276 may be a switchable, via metering valve 1282, pressurized stream of aluminum powder 1286. In practice, Scanner 1280 selectively moves laser 1274 and aluminum source 1276 to solidify a portion of the fresh bed 1266 of iron powder to build up the next layer of the object being fabricated 1268. Here, the laser source 1274 provides sufficient heat such that the aluminum powder stream and the iron oxide layer on the iron powder provide a localized and controlled thermite reaction to selectively solidify the portion of bed 1266 corresponding to the fabricated part 1268. Here, a method of forming a soft magnetic bulk material of a predetermined shape 1268 from a magnetic material 1262 and a non-magnetic material 1286 is provided by providing a reservoir 1266, 1270 adapted to contain the soft magnetic bulk material of the predetermined shape 1268; providing a heat source 1274 and heating the magnetic material 1262 and the non-magnetic material 1286 in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of a predetermined shape 1268. Here, the soft magnetic bulk material 1268 has domains formed from the magnetic material with insulating boundaries formed from the reaction as described with respect to FIGS. 41 and 42.
In another example, FIG. 44, shows an apparatus 1300 that uses an additive principle to form a soft magnetic bulk material that has domains formed from the magnetic material with insulating boundaries formed from the thermite reaction as described. System 1300 has moveable support 1310, heat source 1312 and powder source 1314 and alternate powder source 1316. Scanning platform 1318 selectively positions heat source 1314 and powder sources 1316 to direct heat and material to a portion of support 1310 to turn the powder material from sources 1314, 1316 from powder form to solid form. In practice, iron particles with iron oxide coating are provided within reservoir powder source 1314 and aluminum powder is provided within powder source 1316. In the embodiment shown, support 1310 may be heated, for example, to facilitate the reaction or stress relieve part 1318. To build successive layers of object 1318, indexer 1320 is indexed down an increment to lower support 1310 Scanner 1318 selectively moves heat source 1312, powder source 1314 and alternate powder source 1316 to deposit and solidify a portion the object being fabricated 1319. Herein, indexer, scanner, or the like may include a stage, fixture, robot, head, or other moveable structure typically controlled by a program. The process is repeated until the object being fabricated 1319 is complete. In alternate aspects, scanner 1318 may not be provided, for example, where an x-y scanner or indexer is coupled to support 1310. In the embodiment shown, the switchable, via metering valve 1326, pressurized powder stream 1322 may be iron oxide coated iron particles, the heat source 1312 may be a switchable laser and the alternative powder source 1316 may be a switchable, via metering valve 1328, pressurized stream of aluminum powder 1324. In practice, Scanner 1280 selectively moves laser 1312, iron powder source 1314 and aluminum powder source 1316 to deposit and solidify a portion of the object being fabricated 1319. Here, the laser source 1312 provides sufficient heat such that the aluminum powder stream and the iron oxide layer on the iron powder from the iron powder stream provide a localized and controlled thermite reaction to selectively deposit and solidify the portion to the fabricated part 1318. In alternate aspects, laser may not be provided, for example, where the powder source 1314 heats the iron oxide coated particles to a molten are softened state as disclosed sufficient to provide the heat needed for the thermite reaction. In alternate aspects, aluminum powder source 1316 may not be provided, for example, where the aluminum powder is mixed with the iron powder in source 1314. Accordingly all such aspects may be provided alone or in combination with any of the disclosed embodiments. The disclosed method and apparatus may form a soft magnetic material, for example, having structure similar to the spray or deposition based methods as previously described, for example, as disclosed with respect to FIGS. 23 A& B or otherwise as disclosed. Here, a method of forming a soft magnetic bulk material of a predetermined shape 1318 from a magnetic material 1322 and a non-magnetic material 1324 is provided by providing a reservoir 1310 adapted to contain the soft magnetic bulk material of the predetermined shape 1318; providing a heat source 1312 and heating the magnetic material 1322 and the non-magnetic material 1324 in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of a predetermined shape 1310. Here, the soft magnetic bulk material 1318 has domains formed from the magnetic material with insulating boundaries formed from the reaction as described with respect to FIGS. 41 and 42.
Referring also to FIG. 45, there is shown an alternate aspect of the disclosed embodiment. Apparatus 1350 has mold 1532 with a predetermined shape, bulk material 1354, which may be a combination of iron oxide coated powder and aluminum powder as described and heat source 1356. The heat source triggers a thermite reaction as described turning the powder mixture 1354 into a solid part 1358 as the reaction travels through the part. Here, a method of forming a soft magnetic bulk material of a predetermined shape 1358 from a magnetic material and a non-magnetic material 1354 is provided by providing a reservoir 1352 adapted to contain the soft magnetic bulk material of the predetermined shape 1358; providing a heat source 1356 and heating the magnetic material and the non-magnetic material 1354 in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of a predetermined shape 1358. Here, the soft magnetic bulk material 1358 has domains formed from the magnetic material with insulating boundaries formed from the reaction as described with respect to FIGS. 41 and 42.
1. A system for forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material, the system comprising:
a support configured to support the soft magnetic bulk material of the predetermined shape;
a heating device for heating the magnetic material to form particles having a softened state;
a deposition device for depositing successive layers of particles of the magnetic material in the softened state on the support; and
an indexing mask subsystem configured as a negative of at least a portion of the predetermined shape, the mask subsystem located between the deposition device and the support and indexed relative to the support upon deposition of the successive layers to selectively block the successive layers of particles of the magnetic material in the softened state from being deposited on the support thus forming the soft magnetic bulk material of a predetermined shape on the support.
2. The system of claim 1 wherein the mask subsystem comprises a first and second mask.
3. The system of claim 1 wherein the mask subsystem comprises a first and second mask and wherein the first mask is moveable relative to the second mask.
4. The system of claim 1 wherein the soft magnetic bulk material of a predetermined shape has a uniform cross section.
5. The system of claim 1 wherein the soft magnetic bulk material of a predetermined shape has a non uniform cross section.
6. The system of claim 1 wherein the mask subsystem comprises more than one mask having different shapes corresponding to different cross sections of the soft magnetic bulk material of a predetermined shape with a non uniform cross section at different index positions.
7. A method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material, the method comprising:
providing a deposition device;
providing a support configured to support the soft magnetic bulk material of the predetermined shape;
providing a mask subsystem configured as a negative of at least a portion of the predetermined shape;
heating the magnetic material with the heating device to form particles having a softened state;
locating the mask subsystem between the deposition device and the support;
depositing successive layers of particles of the magnetic material in the softened state with the deposition device on the support; and
indexing, to a position relative to the support, the mask subsystem upon deposition of the successive layers;
wherein the mask subsystem selectively blocks the successive layers of particles of the magnetic material in the softened state from being deposited on the support thus forming the soft magnetic bulk material of a predetermined shape on the support.
8. The method of claim 7 wherein the mask subsystem comprises a first and second mask.
9. The system of claim 7 wherein the mask subsystem comprises a first and second mask and wherein the first mask is moveable relative to the second mask.
10. The method of claim 7 wherein the soft magnetic bulk material of a predetermined shape has a uniform cross section.
11. The method of claim 7 wherein the soft magnetic bulk material of a predetermined shape has a non uniform cross section.
12. The method of claim 7 wherein the mask subsystem comprises more than one mask having different shapes corresponding to different cross sections of the soft magnetic bulk material of a predetermined shape with a non uniform cross section at different index positions.
13. A method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a non-magnetic material, the method comprising: providing a reservoir adapted to contain the soft magnetic bulk material of the predetermined shape;
heating the magnetic material and the non-magnetic material in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of a predetermined shape;
wherein the soft magnetic bulk material of a predetermined shape has domains formed from the magnetic material with insulating boundaries formed from the reaction.
14. The method of claim 13 wherein the reservoir comprises a movable support.
15. The method of claim 13 wherein the heat source comprises a laser.
16. The method of claim 13 wherein the reaction comprises a thermite reaction.
17. The method of claim 13 wherein the domains comprise iron and wherein the insulating material comprises aluminum oxide.
18. The method of claim 13 wherein the reaction comprises a thermite reaction and wherein the magnetic material comprises coated iron particles and wherein the non magnetic material comprises aluminum.
19. The method of claim 13 wherein forming the soft magnetic bulk material of a predetermined shape comprises an additive process.
20. The method of claim 13 wherein the reservoir comprises a mold.
US13836615 2011-06-30 2013-03-15 System and method for making a structured magnetic material with integrated particle insulation Active 2035-05-18 US10022789B2 (en)
US13507448 US20130000447A1 (en) 2011-06-30 2012-06-29 System and method for making a structured magnetic material with integrated particle insulation
US13836615 US10022789B2 (en) 2011-06-30 2013-03-15 System and method for making a structured magnetic material with integrated particle insulation
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JP2016500661A JP6173554B2 (en) 2013-03-15 2014-03-05 System and method for manufacturing a structural magnetic material with integrated particle insulation
US13507448 Continuation-In-Part US20130000447A1 (en) 2011-06-30 2012-06-29 System and method for making a structured magnetic material with integrated particle insulation
US20130292081A1 true true US20130292081A1 (en) 2013-11-07
US10022789B2 US10022789B2 (en) 2018-07-17
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US13836615 Active 2035-05-18 US10022789B2 (en) 2011-06-30 2013-03-15 System and method for making a structured magnetic material with integrated particle insulation
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