Patent ID: 7144468

Claim:
A method of constructing a low core loss, unitary amorphous metal magnetic component for an electric machine, comprising: spirally winding ferromagnetic amorphous metal strip material to form a plurality of layers of a wound cylinder of annular cross-section having cylindrical inner and outer surfaces and two annular faces, said faces being separated by an axial thickness; after winding, performing the following operations; heat treating said cylinder; bonding and curing each of the layers of said wound cylinder to the layers adjacent thereto with an adhesive agent by applying to said wound cylinder an adhesive to at least one of the annular faces wherein said adhesive impregnates the wound cylinder by flowing between the layers; and forming said component by cutting a plurality of slots in at least one of said annular faces, said slots extending between said inner surface and said outer surface and having a depth less than said axial thickness, wherein said ferromagnetic amorphous metal strip has a composition defined essentially by the formula: M 70-85 Y 5-20 Z 0-20 , subscripts in atom percent, where “M” is at least one of Fe, Ni or Co, “Y” is at least one of B, C or P, and “Z” is at least one of Si, Al or Ge; with the provisos that (i) up to 10 atom percent of component “M” can be replaced with at least one of the metallic species Ti, V, Cr, Mn, Cu, Zr, Nb, Mo, Ta, Hf, Ag, Au, Pd, Pt, or W, (ii) up to 10 atom percent of components (Y+Z) can be replaced by at least one of the non-metallic species In, Sn, Sb or Pb and (iii) up to about one (1) atom percent of the components (M+Y+Z) can be incidental impurities.