EP3792944B1 - Method for making a structured magnetic material with integrated particle insulation - Google Patents
Method for making a structured magnetic material with integrated particle insulation Download PDFInfo
- Publication number
- EP3792944B1 EP3792944B1 EP20203613.3A EP20203613A EP3792944B1 EP 3792944 B1 EP3792944 B1 EP 3792944B1 EP 20203613 A EP20203613 A EP 20203613A EP 3792944 B1 EP3792944 B1 EP 3792944B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- domains
- droplets
- spray
- boundaries
- insulating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 239000000696 magnetic material Substances 0.000 title claims description 170
- 238000000034 method Methods 0.000 title claims description 111
- 239000002245 particle Substances 0.000 title claims description 72
- 238000009413 insulation Methods 0.000 title description 65
- 230000005291 magnetic effect Effects 0.000 claims description 118
- 239000011810 insulating material Substances 0.000 claims description 112
- 239000013590 bulk material Substances 0.000 claims description 102
- 238000006243 chemical reaction Methods 0.000 claims description 81
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 68
- 238000010438 heat treatment Methods 0.000 claims description 32
- 229910052742 iron Inorganic materials 0.000 claims description 28
- 230000008569 process Effects 0.000 claims description 24
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 14
- 239000003832 thermite Substances 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- 239000000654 additive Substances 0.000 claims description 3
- 230000000996 additive effect Effects 0.000 claims description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 2
- 239000000463 material Substances 0.000 description 270
- 239000007921 spray Substances 0.000 description 186
- 239000010410 layer Substances 0.000 description 136
- 238000000151 deposition Methods 0.000 description 123
- 230000008021 deposition Effects 0.000 description 113
- 229910045601 alloy Inorganic materials 0.000 description 96
- 239000000956 alloy Substances 0.000 description 96
- 239000007789 gas Substances 0.000 description 94
- 239000011248 coating agent Substances 0.000 description 65
- 238000000576 coating method Methods 0.000 description 65
- 239000007769 metal material Substances 0.000 description 62
- 239000000843 powder Substances 0.000 description 52
- 239000000126 substance Substances 0.000 description 46
- 239000003795 chemical substances by application Substances 0.000 description 42
- 239000000758 substrate Substances 0.000 description 40
- 238000004804 winding Methods 0.000 description 35
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 32
- 239000000203 mixture Substances 0.000 description 28
- 229910052751 metal Inorganic materials 0.000 description 23
- 239000002184 metal Substances 0.000 description 21
- 230000001143 conditioned effect Effects 0.000 description 19
- 238000004519 manufacturing process Methods 0.000 description 18
- 238000002485 combustion reaction Methods 0.000 description 17
- 238000010586 diagram Methods 0.000 description 15
- 239000002923 metal particle Substances 0.000 description 15
- 230000035699 permeability Effects 0.000 description 14
- 238000005507 spraying Methods 0.000 description 14
- 239000000446 fuel Substances 0.000 description 12
- 230000008018 melting Effects 0.000 description 12
- 238000002844 melting Methods 0.000 description 12
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 11
- 230000002250 progressing effect Effects 0.000 description 11
- 230000015572 biosynthetic process Effects 0.000 description 9
- 239000002131 composite material Substances 0.000 description 9
- 230000006698 induction Effects 0.000 description 9
- 239000007787 solid Substances 0.000 description 9
- MWKFXSUHUHTGQN-UHFFFAOYSA-N decan-1-ol Chemical compound CCCCCCCCCCO MWKFXSUHUHTGQN-UHFFFAOYSA-N 0.000 description 8
- 238000013461 design Methods 0.000 description 8
- 230000033001 locomotion Effects 0.000 description 8
- 239000011261 inert gas Substances 0.000 description 7
- 229910001092 metal group alloy Inorganic materials 0.000 description 7
- 238000009718 spray deposition Methods 0.000 description 7
- 230000008901 benefit Effects 0.000 description 6
- 230000001276 controlling effect Effects 0.000 description 6
- 238000001816 cooling Methods 0.000 description 6
- 239000012777 electrically insulating material Substances 0.000 description 6
- 239000000395 magnesium oxide Substances 0.000 description 6
- 239000003570 air Substances 0.000 description 5
- 239000000919 ceramic Substances 0.000 description 5
- 238000005137 deposition process Methods 0.000 description 5
- 230000004907 flux Effects 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 229910000640 Fe alloy Inorganic materials 0.000 description 4
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 238000005474 detonation Methods 0.000 description 4
- SZVJSHCCFOBDDC-UHFFFAOYSA-N ferrosoferric oxide Chemical compound O=[Fe]O[Fe]O[Fe]=O SZVJSHCCFOBDDC-UHFFFAOYSA-N 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- -1 '98 Substances 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 239000000567 combustion gas Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 239000003302 ferromagnetic material Substances 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 3
- 239000011777 magnesium Substances 0.000 description 3
- 239000002244 precipitate Substances 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 239000002699 waste material Substances 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910000531 Co alloy Inorganic materials 0.000 description 2
- 229910000976 Electrical steel Inorganic materials 0.000 description 2
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- QVYYOKWPCQYKEY-UHFFFAOYSA-N [Fe].[Co] Chemical compound [Fe].[Co] QVYYOKWPCQYKEY-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 239000012080 ambient air Substances 0.000 description 2
- 238000000137 annealing Methods 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000013626 chemical specie Substances 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 230000001965 increasing effect Effects 0.000 description 2
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 230000007935 neutral effect Effects 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000011593 sulfur Substances 0.000 description 2
- 229910052717 sulfur Inorganic materials 0.000 description 2
- 229910000859 α-Fe Inorganic materials 0.000 description 2
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- 229910015372 FeAl Inorganic materials 0.000 description 1
- 229910005347 FeSi Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- UJXVAJQDLVNWPS-UHFFFAOYSA-N [Al].[Al].[Al].[Fe] Chemical compound [Al].[Al].[Al].[Fe] UJXVAJQDLVNWPS-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000000889 atomisation Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- 238000001311 chemical methods and process Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 238000004320 controlled atmosphere Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 210000003298 dental enamel Anatomy 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 230000005294 ferromagnetic effect Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000010286 high velocity air fuel Methods 0.000 description 1
- 238000010952 in-situ formation Methods 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 229910021326 iron aluminide Inorganic materials 0.000 description 1
- 239000003350 kerosene Substances 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 239000006249 magnetic particle Substances 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 230000006911 nucleation Effects 0.000 description 1
- 238000010899 nucleation Methods 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 239000012256 powdered iron Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 238000007712 rapid solidification Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 238000000110 selective laser sintering Methods 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 238000006557 surface reaction Methods 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000009692 water atomization Methods 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B1/00—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
- B05B1/02—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape
- B05B1/08—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape of pulsating nature, e.g. delivering liquid in successive separate quantities ; Fluidic oscillators
- B05B1/083—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape of pulsating nature, e.g. delivering liquid in successive separate quantities ; Fluidic oscillators the pulsating mechanism comprising movable parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
- B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
- B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
- B05B7/224—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material having originally the shape of a wire, rod or the like
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
Definitions
- the disclosed embodiment relates to system and method for making a structured material and more particularly making a material having domains with insulated boundaries.
- Electric machines such as DC brushless motors, and the like, may be used in an increasing variety of industries and applications where a high motor output, superior efficiency of operation, and low manufacturing cost often play a critical role in the success and environmental impact of the product, e.g., robotics, industrial automation, electric vehicles, HVAC systems, appliances, power tools, medical devices, and military and space exploration applications.
- These electric machines typically operate at frequencies of several hundred Hz with relatively high iron losses in their stator winding cores and often suffer from design limitations associated with the construction of stator winding cores from laminated electrical steel.
- a typical brushless DC motor includes a rotor, with a set of permanent magnets with alternating polarity, and a stator.
- the stator typically comprises a set of windings and a stator core.
- the stator core is a key component of the magnetic circuit of the motor as it provides a magnetic path through the windings of the motor stator.
- the stator core In order to achieve high efficiency of operation, the stator core needs to provide a good magnetic path, i.e., high permeability, low coercivity and high saturation induction, while minimizing losses associated with eddy currents induced in the stator core due to rapid changes of the magnetic field as the motor rotates.
- This may be achieved by constructing the stator core by stacking a number of individually laminated thin sheet-metal elements to build the stator core of the desired thickness.
- Each of the elements may be stamped or cut from sheet metal and coated with insulating layer that prevents electric conduction between neighboring elements.
- the elements are typically oriented in such a manner that magnetic flux is channeled along the elements without crossing the insulation layers which may act as air gaps and reduce the efficiency of the motor.
- the insulation layers prevent electric currents perpendicular to the direction of the magnetic flux to effectively reduce losses associated with eddy currents induced in the stator core.
- Soft magnetic composites 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.
- 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.
- 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.
- a system for making a material having domains with insulated boundaries includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface and a gas subsystem configured to introduce one or more reactive gases to an area proximate in-flight droplets.
- the one or more reactive gases create an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.
- the droplet spray subsystem may include a crucible configured to create the molten metal alloy direct the molten alloy droplets towards the surface.
- the droplet spray subsystem may include a wire arc droplet deposition subsystem configured to create the molten metal alloy droplets and direct the molten alloy droplets towards the surface.
- the droplet subsystem includes one or more of: a plasma spray droplet deposition subsystem, a detonation spray droplet deposition subsystem, a flame spray droplet deposition subsystem, a high velocity oxygen fuel spray (HVOF) droplet deposition subsystem, a warm spray droplet deposition subsystem, a cold spray droplet deposition subsystem, and a wire arc droplet deposition subsystem each configured to form the metal alloy droplets and direct the alloy droplets towards the surface.
- the gas subsystem may include a spray chamber having one or more ports configured to introduce the one or more reactive gases to the proximate the in-flight droplets.
- the gas subsystem may include a nozzle configured to introduce the one or more reactive gases to the in-flight droplets.
- the surface may be movable.
- the system may include a mold on the surface configured to receive the droplets and form the material having domains with insulated boundaries in the shape of the mold.
- the droplet spray subsystem may include a uniform droplet spray subsystem configured to generate the droplets having a uniform diameter.
- the system may include a spray subsystem configured to introduce an agent proximate in-flight droplets to further improve the properties of the material.
- the one or more gases may include reactive atmosphere.
- the system may include a stage configured to move the surface location in one or more predetermined directions.
- a system for making a material having domains with insulated boundaries includes a spray chamber, a droplet spray subsystem coupled to the spray chamber configured to create molten alloy droplets and direct the molten alloy droplets to a predetermined location in the spray chamber and a gas subsystem configured to introduce one or more reactive gases into the spray chamber.
- the one or more reactive gases create an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.
- a system for making a material having domains with insulated boundaries includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface and a spray subsystem configured to introduce an agent proximate in-flight droplets.
- the agent creates an insulation layer on the droplets in flight such that said droplets form a material having domains with insulated boundaries on the surface.
- a system for making a material having domains with insulated boundaries includes a spray chamber, a droplet spray subsystem coupled to the spray chamber configured to create molten alloy droplets and direct the molten alloy droplets to a predetermined location in the spray chamber and a spray subsystem coupled to the spray chamber configured to introduce an agent.
- the agent creates an insulation layer on said droplets in flight such that said droplets form a material having domains with insulated boundaries on the surface.
- a method for making a material having domains with insulated boundaries includes creating molten alloy droplets, directing the molten alloy droplets to a surface, and introducing one or more reactive gases proximate in-flight droplets such that the one or more reactive gases creates an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.
- the method may include the step of moving the surface in one or more predetermined directions.
- the step of introducing molten alloy droplets may include introducing molten alloy droplets having a uniform diameter.
- the method may include the step of introducing an agent proximate in-flight droplets to improve the properties of the material.
- a method for making a material having domains with insulated boundaries includes creating molten alloy droplets, directing the molten alloy droplets to a surface, and introducing an agent proximate the in-flight droplets to create an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.
- a method for making a material having domains with insulated boundaries includes creating molten alloy droplets, introducing molten alloy droplets into a spray chamber, directing the molten alloy droplets to a predetermined location in the spray chamber, and introducing one or more reactive gases into the chamber such that the one or more reactive gases creates an insulation layer on the droplets in flight so that the droplets form a material having domains with insulated boundaries.
- a material having domains with insulated boundaries includes a plurality of domains formed from molten alloy droplets having an insulation layer thereon and insulation boundaries between the domains.
- a system for making a material having domains with insulated boundaries includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface and a spray subsystem configured to direct a spray of an agent at deposited droplets on the surface.
- the agent creates insulation layers on the deposited droplets such that the droplets form a material having domains with insulated boundaries on the surface.
- the agent may directly form the insulation layers on the deposited droplets to form the material having domains with insulated boundaries on the surface.
- the spray of agent may facilitate and/or participate and/or accelerate a chemical reaction that forms insulation layers on the deposited droplets to form the material having domains with insulated boundaries.
- the droplet spray subsystem may include a crucible configured to create the molten metal alloy direct the molten alloy droplets towards the surface.
- the droplet spray subsystem may include a wire arc droplet deposition subsystem configured to create the molten metal alloy droplets and direct the molten alloy droplets towards the surface.
- a system for making a material having domains with insulated boundaries includes a droplet spray subsystem configured to create and eject molten alloy droplets into a spray chamber and direct the molten alloy droplets to a predetermined location in the spray chamber.
- the spray chamber is configured to maintain a predetermined gas mixture which facilitates and/or participates and/or accelerates in a chemical reaction that forms an insulation layer with deposited droplets to form a material having domains with insulated boundaries.
- the spray of agent may directly create insulation layers on the deposited droplets to form the material having domains with insulated boundaries.
- the spray of agent may facilitate and/or participate and/or accelerate a chemical reaction that form insulation layers on the deposited droplets to form the material having domains with insulated boundaries.
- a method for making a material having domains with insulated boundaries includes creating molten alloy droplets, directing the molten alloy droplets with a nozzle to a surface in one or more spray sub-chambers, maintaining a first predetermined pressure and gas mixture in one of the spray chambers which prevents a reaction of the gas mixture with molten alloy droplets and the spray nozzle, and maintaining a second predetermined pressure and gas mixture in the other of the spray sub-chamber which facilitates and/or precipitates and/or accelerates a chemical reaction that forms an insulation layer on deposited droplets to form a material having domains with insulated boundaries.
- a system for making a material having domains with insulated boundaries includes a combustion chamber, a gas inlet configured to inject a gas into the combustion chamber, a fuel inlet configured to inject a fuel into the combustion chamber, an igniter subsystem configured to ignite a mixture of the gas and the fuel to create a predetermined temperature and pressure in the combustion chamber, a metal powder inlet configured to inject a metal powder comprised of particles coated with an electrically insulating material into the combustion, wherein the predetermined temperature creates conditioned droplets comprised of the metal powder in the chamber, and an outlet configured to eject and accelerate combustion gases and the conditioned droplets from the combustion chamber and towards a stage such that conditioned droplets adhere to the stage to form a material having domains with insulated boundaries thereon.
- the particles of the metal powder may include an inner core made of a soft magnetic material and an outer layer made of the electrically insulating material.
- the conditioned droplets may include a solid outer core and a softened and/or partially melted inner core.
- the outlet may be configured to eject and accelerate the combustion gases and the conditioned droplets from the combustion chamber at a predetermined speed.
- the particles may have a predetermined size.
- the stage may be configured to move in one or more predetermined directions.
- the system may include a mold on the stage to receive the conditioned droplets and form the material having domains with insulated boundaries in the shape of the mold.
- the stage may be configured to move in one or more predetermined directions.
- a system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material.
- the heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on to the support to form the bulk material having insulated boundaries.
- a system for forming a soft magnetic bulk material from a magnetic material and a source of an insulating material includes a heating device coupled to the support and a deposition device coupled to the support, a support configured to support the soft magnetic bulk material.
- the heating device heats the magnetic material to form particles having a softened state and the deposition device deposits particles of the magnetic material in the softened state on the support to form the soft magnetic bulk material and the soft magnetic bulk material has domains formed from the magnetic material with insulating boundaries formed from the source of insulating material.
- 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 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.
- a method of forming a bulk material with insulated boundaries 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.
- Providing the source of insulating material may include providing a reactive chemical source and particles of the metal material in the softened state may be deposited on the support in a deposition path and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source in the deposition path.
- Providing the source of insulating material may include providing a reactive chemical source and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source after the depositing the particles of the metal material in the softened state on to the support.
- the method may include setting the molten state at a temperature above the melting point of the metal material.
- Providing the source of insulating material may include providing a reactive chemical source and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source at the surface of the particles.
- Depositing particles may include uniformly depositing the particles on the support.
- Providing the source of insulating material may include providing a reactive chemical source and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source in a reactive atmosphere.
- Providing the source of insulating material may include providing 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 co-spraying of the agent.
- the method may include forming the insulating boundaries by co-spraying the insulating material.
- the method may include forming the insulating boundaries 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 metal material.
- a method of forming a soft magnetic bulk material includes providing a magnetic material, providing a source of insulating material, providing a support configured to support the soft magnetic bulk material, heating the magnetic material to a softened state, and depositing particles of the magnetic material in the softened state on to support to form the soft magnetic bulk material having domains formed from the magnetic material with insulating boundaries.
- a bulk material formed on a surface includes a plurality of adhered domains of metal material, substantially all of the domains of the plurality of domains of metal material separated by a predetermined layer of high resistivity insulating material. A first portion of the plurality of domains forms a surface.
- a second portion of the plurality of domains includes successive domains of metal material progressing from the first portion, substantially all of the domains in the successive domains each include a first surface and second surface, the first surface opposing the second surface, the second surface conforming to a shape of progressed domains, and a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- the layer of high resistivity insulating material may include a material having a resistivity greater than about 1 ⁇ 10 3 ⁇ -m.
- the layer of high resistivity insulating material may have a selectable substantially uniform thickness.
- the metal material may comprise a ferromagnetic material.
- the layer of high resistivity insulating material may comprise ceramic.
- the first surface and the second surface may form an entire surface of the domain. The first surface may progress in a substantially uniform direction from the first portion.
- a soft magnetic bulk material formed on a surface includes a plurality of domains of magnetic material, each of the domains of the plurality of domains of magnetic material substantially separated by a selectable coating of high resistivity insulating material.
- a first portion of the plurality of domains forms a surface.
- a second portion of the plurality of domains includes successive domains of magnetic material progressing from the first portion, substantially all of the domains in the successive domains of magnetic material in the second portion each include a first surface and a second surface, the first surface comprising a substantially convex surface, and the second surface comprising one or more substantially concave surfaces.
- an electrical device coupled to a power source 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 more substantially concave surfaces.
- an electric motor coupled to a power source includes a frame, a rotor coupled to the frame, a stator coupled to the frame, at least one of the rotor or the stator including a winding coupled to the power source and a soft magnetic core.
- the winding is wound about a portion of the soft magnetic core.
- 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 include a first surface and a second surface, the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- a soft magnetic bulk material formed on a surface includes a plurality of adhered domains of magnetic material, substantially all of the domains of the plurality of domains of magnetic material separated by a layer of high resistivity insulating material.
- a first portion of the plurality of domains forms a surface.
- a second portion of the plurality of domains includes successive domains of magnetic material progressing from the first portion, substantially all of the domains in the successive domains each including a first surface and a second surface, the first surface opposing the second surface, the second surface conforming to the shape of progressed domains.
- a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- Substantially all of the successive domains each include a first surface and a second surface, the first surface opposing the second surface, the second surface conforming to the shape of progressed domains of metal material, and a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- an electrical device coupled to a power source 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, each of the domains of the plurality of domains substantially separated by a layer of high resistivity insulating material.
- the plurality of domains include successive domains of magnetic material progressing through the soft magnetic core.
- Substantially all of the successive domains each include a first surface and a second surface, the first surface opposing the second surface, the second surface conforming to the shape of progressed domains of metal material, and a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- a system for forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material 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.
- a method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material 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.
- a method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a non-magnetic material 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.
- System 10 includes droplet spray subsystem 12 configured to create molten alloy droplets 16 and direct molten alloy droplets 16 towards surface 20.
- droplet spray subsystem 12 directs molten alloy droplets into spray chamber 18.
- spray chamber 18 is not required as will be discussed below.
- droplet spray subsystem 12 includes crucible 14 which creates molten alloy droplets 16 and directs molten alloy droplets 16 towards surface 20.
- Crucible 14 may include heater 42 which forms molten alloy 44 in chamber 46.
- the material used to make molten alloy 44 may have a high permeability, low coercivity and high saturation induction.
- Molten alloy 44 may be made from a magnetically soft iron alloy, such as iron-base alloy, iron-cobalt alloy, nickel-iron alloy, silicon iron alloy, iron-aluminide, ferritic stainless steel, or similar type alloy.
- Chamber 46 may receive inert gas 47 via port 45. Molten alloy 44 may be ejected through orifice 22 due to the pressure applied from inert gas 47 introduced via port 45.
- Actuator 50 with vibration transmitter 51 may be used to vibrate a jet of molten alloy 44 at a specified frequency to break up molten alloy 44 into stream of droplets 16 which are ejected through orifice 22.
- Crucible 14 may also include temperature sensor 48. Although as shown crucible 14 includes one orifice 22, in alternate, crucible 14 may have any number of orifices 22 as needed to accommodate higher deposition rates of droplets 16 on surface 20, e.g., up to 100 orifices or more.
- Droplet spray subsystem 12' includes wire arc droplet deposition subsystem 250 which creates molten alloy droplets 16 and directs molten alloy droplets 16 towards surface 20.
- Wire arc droplet deposition subsystem 250 includes chamber 252 which houses positive wire arc wire 254 and negative arc wire 256. Alloy 258 is preferably disposed in each of wire arc wires 254 and 256.
- Alloy 258 may be used to create droplets 16 to be directed toward surface 20 and may be composed mainly of iron (e.g., greater than about 98%) with very low amount of carbon, sulfur, and nitrogen content, (e.g., less than about 0.005%) and may include minute quantities of Cr (e.g., less than about 1%) with the balance, in this example, being Si or Al to achieve good magnetic properties.
- the metallurgical composition may be tuned to provide improvements in the final properties of the material having domains with insulated boundaries.
- Nozzle 260 may be configured to introduce one or more gases 262 and 264, e.g., ambient air, argon, and the like, to create gas 268 inside chamber 252.
- Pressure control valve 266 controls the flow of one or more of gases 262, 264 into chamber 252.
- the voltage applied to positive arc wire 254 and negative arc wire 256 creates arc 270 which causes alloy 258 to form molten alloy droplets 16 which are directed towards surface 20.
- voltages between about 18 and 48 volts and currents between about 15 to 400 amperes may applied to positive wire arc 254 and negative arc wire 256 to provide a continuous wire arc spray process of droplets 16.
- system 10 includes spray chamber 16.
- System 10', Fig. 3 includes droplet spray subsystem 12" with wire arc droplet deposition subsystem 250' that creates molten alloy droplets 16 and directs molten alloy droplets 16 towards surface 20.
- system 10' does not include chamber 252, Fig. 2 , and chamber 18, Figs. 1 and 2 .
- nozzle 260, Fig. 3 may be configured to introduce one or more gases 262 and 264 to create gas 268 in the area proximate positive arc wire 254 and negative arc wire 256. Similar as discussed above with reference to Fig.
- System 10 may include droplet spray deposition subsystem 12′′′ having wire arc droplet deposition subsystem 250" having a plurality of positive arc wire 254, negative arc wires 256 and nozzles 260 which may be used simultaneously to achieve higher spray deposition rates of molten alloy droplets 16 on surface 20.
- Wire arcs 254, 256, and similar deposition devices discussed above may be provided in different directions to form the material having domains of insulated boundaries.
- Wire arc droplet deposition subsystem 250" is not enclosed in a chamber.
- wire arc spray 250" may be enclosed in chamber, e.g., chamber 252, Fig. 2 .
- shroud 261, Fig. 4 may be used to contain reactive gas 26 and droplets 16 in the area proximate surface 20.
- droplet spray subsystem 12 may utilize a plasma spray droplet deposition subsystem, a detonation spray droplet deposition subsystem, a flame spray droplet deposition subsystem, a high velocity oxy-fuel spray (HVOF) droplet deposition subsystem, a warm spray droplet deposition subsystem, a cold spray droplet deposition subsystem, or any similar type spray droplet deposition subsystems.
- a plasma spray droplet deposition subsystem a detonation spray droplet deposition subsystem
- a flame spray droplet deposition subsystem a high velocity oxy-fuel spray (HVOF) droplet deposition subsystem
- HVOF high velocity oxy-fuel spray
- warm spray droplet deposition subsystem a cold spray droplet deposition subsystem
- any suitable deposition system may be used in accordance with one or more of disclosed embodiments discussed above.
- Droplet spray subsystem 12 may be mounted on a single or plurality of robotic arms and/or mechanical arrangements so as to improve part quality, reduce spray time, and improve process economics.
- the subsystems may spray droplets 16 simultaneously at the same approximate location or may be staggered so as the spray a certain location in a sequential manner.
- Droplet spray subsystem 12 may be controlled and facilitated by controlling one or more of the following spray parameters: wire speed, gas pressure, shroud gas pressure, spraying distance, voltage, current, speed of substrate motion, and/or the speed of arc tool movement.
- System 10, Figs. 1 and 2 also may include port 24 coupled to spray chamber 18 configured to introduce gas 26, e.g., reactive atmosphere, into spray chamber 28.
- System 10', 10", Figs. 3 and 4 may introduce gas 26, e.g., reactive atmosphere, in the area proximate droplets 16 in flight.
- Gas 26 may be chosen such that it creates an insulation layer on droplets 16 as they are in flight towards surface 20.
- a mixture of gases, one or more of which may participate in the reaction with droplets 16, may be introduced to the area proximate droplets 16 in flight.
- Caption 28, Fig. 1 shows an example of insulation layer 30 being formed on in-flight molten alloy droplets 16, Figs. 1-4 , during their flight to surface 20.
- Fig. 5A shows an example of material 32 that includes domains 34 with insulated boundaries 36 therebetween. Insulated boundaries 36 are formed from the insulation layer on droplets 16, e.g., insulation layer 30, Fig. 1 .
- Material 32, Fig 5A may include boundaries 36 between neighboring domains 34 which are virtually perfectly formed as shown.
- material 32, Fig. 5B may include boundaries 36 between neighboring domains 34 with discontinuities as shown.
- Material 32, Figs. 5A and 5B reduces eddy current losses, and discontinuities in boundaries 36 between neighboring domains 34 improve the mechanical properties of material 32. The result is that material 32 may preserve a high permeability, a low coercivity and a high saturation induction of the alloy.
- System 10 and the method thereof may be a single step, fully automated process which saves time and money and produces virtually no waste. In alternate aspects of the disclosed embodiment, system 10 may be operated manually, semi automatically or otherwise.
- System 10"', Fig. 6 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.
- system 10', Fig. 3 , and system 10 Fig.
- agent 64 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 gas exhaust port 100, Fig. 6 .
- Exhaust port 100 may be used to expel excessive gas 26 introduced by port 24 and/or excessive agent 64 introduced by spray subsystem 60.
- exhaust port 100 allows gas 26 to be replaced in spray chamber 18 in a controlled manner.
- system 10', Fig. 3 , and system 10", Fig. 4 may also include a gas exhaust port.
- 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.
- controllable valve 108, Fig. 6 , coupled to port 45 may be utilized to control the flow of inert gas into chamber 46.
- 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.
- System 10, Figs. 1, 2 , and 6 may include a device for measuring the temperature of the deposited droplets 16 on material 32 and a device for controlling the temperature of the deposited droplets on material 32.
- System 10 may include spray subsystem 60 which includes at least one port, e.g., port 62 and/or port 63, which is configured to introduce agent 80 into spray chamber 18.
- a reactive gas may not be utilized.
- Spray subsystem 60 creates spray 86 and/or spray 87 of spray agent 80 which coats droplets 16 with agent 80 to form insulation coating 30, Fig. 1 , on droplets 16 while they are in flight toward surface 20. This creates material 32 having domains 34, Figs 5A-5B , with insulated boundaries 36, e.g., as discussed above.
- Droplet spray subsystem 12 may be a uniform droplet spray system configured to generate droplets 16 having a uniform diameter.
- System 10 may be an alternative material and manufacturing process for the motor cores, or any similar type device which may benefit from a material having domains with insulated boundaries as will be described in greater detail below.
- the stator winding cores of an electric motor may be fabricated using the system and method of one or more embodiments of this invention.
- System 10 may be a single-step net-shape fabrication process which preferably uses droplet spray deposition subsystem 12 and reactive atmosphere introduced by port 24 to facilitate controlled formation of insulation layers 30 on the surfaces of droplets 16, as discussed above with reference to Figs. 1-7 .
- the material chosen to form droplets 16 makes material 32 highly permeable with low coercivity and high saturation induction. Boundaries 36, Figs. 5A-5B may somewhat deteriorate the capability of material 32 to provide good magnetic paths. However, because boundaries 36 may be very thin, e.g., about 0.05 ⁇ m to about 5.0 ⁇ m, and because material 32 may be very dense, this deterioration is relatively small. This, in addition to the low cost of making material 32, is another advantage over conventional SMC, discussed in the Background Section above, which have larger gaps between individual grains as the mating surfaces of neighboring grains of metal powder in SMC do not match perfectly. Insulation boundaries 36 limit electrical conductivity between neighboring domains 34. Material 32 provides a superior magnetic path due to its permeability, coercivity and saturation characteristics. The limited electrical conductivity of material 30 minimizes eddy current losses associated with rapid changes of the magnetic field as the motor rotates.
- 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 cogging 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. Patent 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.
- metal in a crucible is melted by a heater and ejected through an orifice by pressure applied from an inert gas supply.
- the ejected molten metal forms a laminar jet, which is vibrated by a piezoelectric transducer at a specified frequency.
- the disturbance from the vibration causes a controlled breakup of the jet into a stream of uniform droplets.
- a charging plate may be utilized in some applications to electrically charge the droplets so that they repel each other, preventing merging.
- 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.
- 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.
- a gas 26 e.g., reactive atmosphere or similar type gas
- system 10 and the methods thereof forms an insulation layer on in-flight droplets to form a material having domains with insulated boundaries.
- system 310, Fig. 8 , and the method thereof forms the insulation layer on droplets which have been deposited on a surface or substrate to form a material having domains with insulated boundaries.
- System 310 includes droplet spray subsystem 312 configured to create and eject molten alloy droplets 316 from orifice 322 and direct molten alloy droplets 316 towards surface 320.
- droplet spray subsystem 312 ejects molten alloy droplets into spray chamber 318.
- spray chamber 318 may not be required as discussed in further detail below.
- Droplet spray subsystem 312 may include crucible 314 which creates molten alloy droplets 316 and directs molten alloy droplets 316 towards surface 320 inside spray chamber 318.
- crucible 314 may include heater 342 which forms molten alloy 344 in chamber 346.
- the material used to make molten alloy 344 may have a high permeability, low coercivity and high saturation induction.
- molten alloy 344 may be made from a magnetically soft iron alloy, such as iron-base alloy, iron-cobalt alloy, nickel-iron alloy, silicon iron alloy, ferritic stainless steel or similar type alloy.
- Chamber 346 receives inert gas 347 via port 345.
- molten alloy 344 is ejected through orifice 322 due to the pressure applied from inert gas 347 introduced via port 345.
- Actuator 350 with vibration transmitter 351 vibrates a jet of molten alloy 344 at a specified frequency to break up molten alloy 344 into stream of droplets 316 which are ejected through orifice 322.
- Crucible 314 may also include temperature sensor 348. Although as shown crucible 314 includes one orifice 322, in other examples, crucible 314 may have any number of orifices 322 as needed to accommodate higher deposition rates of droplets 316 on surface 320, e.g., up to 100 orifices or more. Molten alloy droplets 316 are ejected from orifice 322 and directed toward a surface 320 to form substrate 512 thereon as will be discussed in greater detail below.
- Surface 320 is preferably moveable, e.g., using stage 340, which may be an X-Y stage, a turn table, a stage that can additionally change the pitch and roll angle of surface 320, or any other suitable arrangement that can support substrate 512 and/or move substrate 512 in a controlled manner as it is formed.
- system 310 may include a mold (not shown) that is placed on surface 320 to which substrate 512 fills the mold.
- System 310 also may include one or more spray nozzles, e.g., spray nozzle 500 and/or spray nozzle 502, configured to direct agent at substrate 512 of deposited droplets 316 and create spray 506 and/or spray 508 of agent 504 that is directed onto or above surface 514 of substrate 512.
- spray nozzle 500 and/or spray nozzle 502 are coupled to spray chamber 318.
- Spray 506 and/or spray 508 may form the insulating layer on surface of deposited droplets 316 before or after droplets 316 are deposited on substrate 512, either by directly forming the insulating layer on droplets 316 or by facilitating, participating, and/or accelerating a chemical reaction that forms the insulating layer on the surface of droplets 316 deposited on surface 320.
- spray 506, 508 of agent 504 may be used to facilitate, participate, and/or accelerate a chemical reaction that forms insulation layers on deposited droplets 316 that form substrate 512 or that are subsequently deposited on substrate 512.
- spray 506, 508 may be directed at substrate 512, Fig. 9 , indicated at 511.
- spray 506, 508 facilitates, accelerates, and/or participates in a chemical reaction with substrate 512 (and subsequent layers of deposited droplets 316 thereon) to form insulating layer 530 on the surface of deposited droplets 316 as shown.
- spray 506, 508 facilitates, accelerates and/or participates, a chemical reaction to form and insulation layers 330 on the subsequent deposited layers of droplets, e.g., as indicated at 513, 515.
- Material 332 is created having domains 334 with insulated boundaries 336 there between.
- 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.
- material 332, Fig 10A includes boundaries 336 between neighboring domains 334 which are virtually perfectly formed as shown.
- 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.
- 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. 11 shows one embodiment of system 310, Fig. 8 , wherein spray 506, 508, instead of facilitating, participating, and/or accelerating a chemical reaction to form insulation layer as shown in Fig. 9 directly forms insulation layers 330, Fig. 8 , on deposited droplets 316 on substrate 512.
- substrate 512 is moved, e.g., in the direction indicated by arrow 517, using stage 340, Fig. 8 .
- Spray 506, 508, Fig. 11 is then directed at deposited droplets 316 on substrate 512, indicated at 519. Insulation layer 330 then forms on each of the deposited droplets 316 as shown.
- 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 form insulation layer 330 indicated at 527, 529.
- material 332 is created which includes domains 334 with insulated boundaries 336, e.g., as discussed above with reference to Figs. 10A-10B .
- Insulating layer 330 on deposited droplets 16 may be formed by a combination of any of the processes discussed above with reference to one or more of Figs. 8-12 . The two processes may take place in sequence or simultaneously.
- agent 504 that creates spray 506 and/or spray 508, Figs. 8-12 may be ferrite powder, a solution containing ferrite powder, an acid, water, humid air or any other suitable agent involved in the process of producing an insulating layer on the surface of the substrate.
- System 310' 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.
- the predetermined pressure in sub-chamber 526 may be higher than the predetermined pressure in sub-chamber 528 to limit the flow of gas from sub-chamber 526 to sub-chamber 528.
- the substantially neutral gas mixture in sub-chamber 526 may be utilized to prevent reaction with droplets 316 with orifice 322 on the surface of droplets 316 before they land on the surface of substrate 512.
- the substantially reactive gas mixture in sub-chamber 528 may be introduced to participate, facilitate and/or accelerate in a chemical reaction with substrate 512, and subsequent layers of deposited droplets 316, to form an insulating layer 330 on deposited droplets 316.
- deposited droplets 316 may be formed on deposited droplets 316 after they land on substrate 512.
- the deposited droplets 316 react with the reactive gas in sub-chamber 528, Fig. 13 which facilitates, participates, and/or accelerates a chemical reaction to create insulation layer 330 indicated at 531.
- the gas in sub-chamber 528 may facilitate, participates, and/or accelerates a reaction with droplets 316 to create insulation layers 330 on substrate 512, indicated at 533 and 535.
- Material 332 having domains 334 with insulated boundaries 336 there between is then formed, e.g., as discussed above with reference to Figs 10A-10B .
- System 310 Fig. 15 , where like parts have like numbers, preferably includes chamber 314 with only one chamber 528.
- droplets 316 are directed directly into chamber 528 which is preferably designed to minimize the travel distance of droplets 316 between orifice 322 and surface 510 of substrate 512. This preferably limits the exposure of droplets 316 to the substantially reactive gas mixture in sub-chamber 528.
- System 310" creates material 332 in a similar manner to system 310', Fig. 14 .
- system 310 For the deposition process of droplets 316, system 310, Figs. 8-9 and 11-15 provides for moving substrate 512 on surface 320 of stage 340 with respect to the stream of droplets 316 ejected from the crucible 314 or similar type device.
- System 310 may also provide for deflecting droplets 316, for example, with magnetic, gas flow or other suitable deflection system. Such deflection may be used alone or in combination with stage 340. In either case, droplets 316 are deposited in a substantially discrete manner, i.e., two consecutive droplets 316 may exhibit limited or no overlap upon deposition.
- v l ⁇ 1 f ⁇ d s > 0
- v l speed of substrate
- f frequency of deposition, i.e., frequency of ejection of droplets 316 from crucible 314, and
- d s diameter of splat formed by a droplet after landing on the surface of the substrate.
- Examples of the one of more aspects of the disclosed embodiment of system 310 performing discrete deposition of droplets 316 are shown in one or more of Figs. 8-9 and 11-15 .
- the relative motion of substrate 512 with respect to the stream of droplets 316 may be controlled so that discrete deposition across an area of a substrate is achieved, e.g., as shown in Fig. 16 .
- the motion of substrate 512 on stage 340, Figs. 8 , 13 and 15 may be controlled so that rows A, B and C, Fig. 16 , are deposited consecutively in a discrete manner.
- rows A 1 , B 1 , C 1 may represent the first layer, indicated as Layer 1
- rows A 2 , B 2 , C 2 may represent the second layer, indicated as Layer 2
- rows A 3 , B 3 , C 3 may represents the third layer, indicated by Layer 3 of the deposited droplets 316.
- the layer arrangement may repeat itself after the third layer, i.e., the layer following Layer 3 will be identical in spacing and positioning as Layer 1.
- the layers may repeat after every second layer. Alternately, any suitable combination of layers or patterns may be provided.
- System 310 may include nozzle 323 having plurality of spaced orifices, e.g., spaced orifices 322, Fig. 17 , employed to deposit multiple rows of droplets 316 simultaneously to achieve higher deposition rates.
- nozzle 323 having plurality of spaced orifices, e.g., spaced orifices 322, Fig. 17 , employed to deposit multiple rows of droplets 316 simultaneously to achieve higher deposition rates.
- the deposition process of droplets 316 discussed above may result in material 332 having domains with insulated boundaries there between, discussed in detail above.
- droplet spray subsystem 312 is shown having crucible 314 configured to eject molten alloy droplets 316 into spray chamber 318, this is not a necessary limitation of the disclosed embodiment.
- System 310, Fig. 18 may include droplet spray subsystem 312'.
- droplet spray subsystem 312' preferably includes wire arc droplet spray subsystem 550 which creates molten alloy droplets 316 and directs molten alloy droplets 316 towards surface 320 inside spray chamber 318.
- Wire arc droplet spray subsystem 550 also preferably includes chamber 552 which houses positive wire arc wire 554 and negative arc wire 556.
- Alloy 558 may be disposed in each of arc wires 554 and 556.
- alloy 558 used to create droplets 316 sprayed toward substrate 512 may be composed mainly of iron (e.g., greater than about 98%) with very low amount of carbon, sulfur, and nitrogen content, (e.g., less than about 0.005%) and may include minute quantities of Al and Cr (e.g., less than about 1%) with the balance, in this example, being Si to achieve good magnetic properties.
- the metallurgical composition may be tuned to provide improvements in the final properties of the material having domains with insulated boundaries.
- Nozzle 560 is shown configured to introduce one or more gases 562 and 564, e.g., ambient air, argon, and the like, to create gas 568 inside chamber 552 and chamber 318.
- gases 562 and 564 e.g., ambient air, argon, and the like
- pressure control valve 566 controls the flow of one or more of gases 562, 564 into chamber 552.
- the voltage applied to positive arc 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.
- 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.
- surrounding gas 568 may be atmospheric air.
- oxide layers may form on iron droplets 316. These oxide layers may include several chemical species, including, e.g., FeO, FezOs, Fe 3 O 4 , and the like. Among these species, FeO and Fe 2 O 3 may have resistivities eight to nine orders of magnitude higher than pure iron. In contrast, Fe 3 O 4 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.
- system 310"', Fig. 19 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.
- droplet spray subsystem 312" does not include chamber 552, Fig. 18 , and chamber 318.
- 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.
- 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.
- 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 .
- a shroud e.g., shroud 523, may surround spray 506 and/or spray 508 of agent 504 and droplets 316 deposited on substrate 512.
- droplet spray subsystem 312 shown in one or more of Figs. 8-19 may include one or more of a plasma spray droplet deposition subsystem, a detonation spray droplet depositions subsystem, a flame spray droplet deposition subsystem, a high velocity oxygen fuel spray (HVOF) droplet deposition subsystem, a warm spray droplet deposition subsystem, a cold spray droplet deposition subsystem, and a wire arc droplet deposition subsystem, each configured to form the metal alloy droplets and direct the molten alloy droplets towards surface 320.
- HVOF high velocity oxygen fuel spray
- Wire arc spray droplet deposition subsystem 550 may form the insulating boundaries by controlling and facilitating one or more of the following spray parameters: wire speed, gas pressure, shroud gas pressure, spraying distance, voltage, current, speed of substrate motion, and/or the speed of arc tool movement.
- One or more of the following process choices may also be optimized to attain improved structure and properties of the material having domains with insulated boundaries: composition of wires, composition of shroud gas/atmosphere, preheating or cooling of atmosphere and/or substrate, in process cooling and/or heating of substrate and/or part.
- a composition of two or more gases may be employed in addition to pressure control to improve process outcomes.
- Droplet spray subsystem 312 Figs. 8 , 13 , 15 , 18 , 19, and 20 may be mounted on a single or plurality of robotic arms and/or mechanical arrangements so as to improve part quality, reduce spray time, and improve process economics.
- the subsystems may spray droplets 316 simultaneously at the same approximate location or may be staggered so as the spray a certain location in a sequential manner.
- Droplet spray subsystem 312 may be controlled and facilitated by controlling one or more of the following spray parameters: wire speed, gas pressure, shroud gas pressure, spraying distance, voltage, current, speed of substrate motion, and/or the speed of arc tool movement.
- the overall magnetic and electric properties of the formed material having domains with insulated boundaries may be improved by regulating the properties of the insulating material.
- the permeability and resistance of the insulating material has a significant impact on the net properties.
- the properties of the net material having domains with insulated boundaries may thus be improved by adding agents or inducing reactions which improve the properties of the insulation, e.g., the promotion of Mn, Zn spinel formation in iron oxide based insulation coating may significantly improve the overall permeability of the material.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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).
- 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.
- conditioned droplets 638 have a soft and/or partially melted inner core 632 made of a soft magnetic material and a solid outer layer 634 made of the electrically insulated material.
- Conditioned droplets 638 are then accelerated and ejected from outlet 624 as stream 640 that includes both combustion gases and conditioned droplets 638.
- stream 640 includes both combustion gases and conditioned droplets 638.
- droplets 638 in stream 640 preferably have a completely solid outer layer 634 and a softened and/or partially melted inner core 632.
- Stream 640 carrying conditioned droplets 638, is directed at stage 644.
- Stream 640 is preferably traveling in a predetermined speed, e.g., about 350m/s.
- Conditioned droplets 638 then impact stage 644 and adhere thereto to form material 648 having domains with insulated boundaries thereon.
- Caption 650 shows in further detail one example of material 648 with domains 650 of soft magnetic material with electrically insulated boundaries 652.
- Fig. 22A shows an example of material 48 that includes domains 650 with insulated boundaries 652 therebetween.
- material 648 includes boundaries 652 between neighboring domains 650 which are virtually perfectly formed as shown.
- 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.
- System 10, 310, and 610 shown in one or more of Figs. 1-22B provides for forming bulk material 32, 332, 512, 648 from metal material 44, 344, 558, 624 and source 26, 64, 504, 634 of insulating material where the metal material and the insulating material may be any suitable metal or insulating material.
- System 10, 310, 610 for forming the bulk material includes, e.g., support 40, 320, 644 configured to support the bulk material. Support 40, 320, 644 may have a flat surface as shown or alternately may have any suitably shaped surface(s), for example where it is desired for the bulk material to conform to the shape.
- System 10, 310, 610 also includes heating device, e.g., 42, 254, 256, 342, 554, 556, 612, a deposition device, e.g., deposition device 22, 270, 322, 570, 624, and a coating device, e.g., coating device 24, 263, 500, 502.
- the deposition device may be any suitable deposition device, for example, by pressure, field, vibration, piezo electric, piston and orifice, by back pressure or pressure differential, ejection or otherwise any suitable method.
- the heating device heats the metal material to a softened or molten state.
- the heating device may be by electric heating elements, induction, combustion or any suitable heating method.
- the coating device coats the metal material with the insulating material.
- the coating device may be by direct application, chemical reaction with gas, solid or liquid(s), reactive atmosphere, mechanical fusion, Sol-gel, spray coating, spray reaction or any suitable coating device, method, or combination thereof.
- the deposition device deposits particles of the metal material in the softened or molten state on to the support forming the bulk material.
- the coating may be a single or multi-layer coating.
- the source of insulating material may be a reactive chemical source where the deposition device deposits the particles of the metal material in the softened or molten state on to the support in a deposition path 16, 316, 640 where insulating boundaries are formed on the metal material by the coating device from a chemical reaction of the reactive chemical source in the deposition path.
- the source of insulating material may be a reactive chemical source where insulating boundaries are formed on the metal material by the coating device from a chemical reaction of the reactive chemical source after the deposition device deposits the particles of the metal material in the softened or molten state on to the support.
- the source of insulating material may be a reactive chemical source where the coating device coats the metal material 34, 334, 642 with the insulating material forming insulating boundaries 36, 336, 652 from a chemical reaction of the reactive chemical source at the surface of the particles.
- the deposition device may be a uniform droplet spray deposition device.
- the source of insulating material may be a reactive chemical source where the coating device coats the metal material with the insulating material forming insulating boundaries formed from a chemical reaction of the reactive chemical source in a reactive atmosphere.
- the source of insulating material may be a reactive chemical source and an agent where the coating device coats the metal material with the insulating material forming 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 metal material with the insulating material forming insulating boundaries formed from a co-spraying of the insulating material.
- the coating device may coat the metal material with the insulating material forming insulating boundaries formed from a chemical reaction and a coating from the source of insulating material.
- the bulk material has domains 34, 334, 650 formed from the metal material with insulating boundaries 36, 336, 652 formed from the insulating material.
- the softened state may be at a temperature below the melting point of the metal material where the deposition device may deposit the particles simultaneously while the coating device coats the metal material with the insulating material.
- the coating device may coat the metal material with the insulating material after the deposition device deposits the particles.
- the system may be provided for forming a soft magnetic bulk material 32, 332, 512, 648 from a magnetic material 44, 344, 558, 624 and a source 26, 64, 504, 634 of insulating material.
- the system for forming the soft magnetic bulk material may have a support 40, 320, 644 configured to support the soft magnetic bulk material.
- Heating device 42, 254, 256, 342, 554, 556, 612 and a deposition device 22, 270, 322, 570, 612 may be coupled to the support.
- the heating device heats the magnetic material to a softened state and the deposition device deposits particles 16, 316, 638 of the magnetic material in the softened state on to the support forming the soft magnetic bulk material where the soft magnetic bulk material has domains 34, 334, 650 formed from the magnetic material with insulating boundaries 36, 336, 652 formed from the source of insulating material.
- the softened state may be at a temperature above or below the melting point of the magnetic material.
- Bulk material 700 may be a soft magnetic material and may have features as discussed above, for example, with respect to material 32, 332, 512, 648 or otherwise.
- a soft magnetic material may have properties of low coercivity, high permeability, high saturation flux, low eddy current loss, low net iron loss or with properties of ferromagnetic, iron, electrical steel or other suitable material.
- a hard magnetic material has high coercivity, high saturation flux, high net iron loss or with properties of magnets or permanent magnets or other suitable material.
- FIG. 23A and 23B also show cross sections of spray deposited bulk material, for example, a cross section of the multi layered material as shown, e.g., in Fig. 16 .
- bulk material 700 Figs. 23A and 23B
- Bulk material 700 has a plurality of adhered domains 710 of metal material, substantially all of the domains of the plurality of domains of metal material separated by a predetermined layer of high resistivity insulating material 712.
- the metal material may be any suitable metal material.
- a first portion 714 of the plurality of domains of metal material is shown forming a formed surface 716 corresponding to the surface 702.
- a second portion 718 of the plurality of domains 710 of metal material is shown having successive domains, e.g., domains 720, 722 of metal material progressing from the first portion 714.
- Substantially all of the domains in the successive domains 720, 722 ... of metal material having first 730 and second 732 surfaces, respectively, first surface opposing the second surface, the second surface conforming to the shape of the domains of metal material that the second surface has progressed from, e.g., as indicated by arrow 733 between first surface 730 and second surface 732.
- a majority of the domains in the successive domains of metal material have the first surface being a substantially convex surface and the second surface having one or more substantially concave surfaces.
- the layer of high resistivity insulating material may be any suitable electrically insulating material.
- the layer may be selected from materials having a resistivity greater than about 1 ⁇ 10 3 ⁇ -m.
- the electrically insulating layer or coating may have high electrical resistivity, such as with materials alumina, zirconia, boron nitride, magnesium oxide, magnesia, titania or other suitable high electrical resistivity material.
- the layer may be selected from materials having a resistivity greater than about 1 ⁇ 10 8 ⁇ -m.
- the layer of high resistivity insulating material may have a selectable thickness that is substantially uniform, for example, as disclosed.
- the metal material may also be a ferromagnetic material.
- the layer of high resistivity insulating material may be ceramic.
- the first surface and the second surface may form an entire surface of the domain.
- the first surfaces may progress in a substantially uniform direction from the first portion.
- Bulk material 700 may be a soft magnetic bulk material formed on surface 702 where the soft magnetic bulk material has a plurality of domains 710 of magnetic material, each of the domains of the plurality of domains of magnetic material substantially separated by a selectable coating of high resistivity insulating material 712.
- a first portion 714 of the plurality of domains of magnetic material may form a formed surface 716 corresponding to surface 702 while a second portion 718 of the plurality of domains of magnetic material has successive domains 720, 722... of magnetic material progressing from the first portion 714.
- Substantially all of the domains in the successive domains of magnetic material have first 730 and second 732 surfaces with the first surface having a substantially convex surface and the second surface having one or more substantially concave surfaces.
- voids 740 may exist in material 700 shown in Fig. 23B .
- the magnetic material may be a ferromagnetic material and the selectable coating of high resistivity insulating material may be ceramic with the first surface substantially opposing the second surface and with the first surfaces progressing in a substantially uniform direction 741 from the first portion 714.
- the electrical device has a soft magnetic core with material as disclosed herein and a winding coupled to the soft magnetic core and surrounding a portion of the soft magnetic core with the winding coupled to the power source.
- the core may have a plurality of domains of magnetic material, each of the domains of the plurality of domains of magnetic material substantially separated by a layer of high resistivity insulating material.
- the plurality of domains of magnetic material may have successive domains of magnetic material progressing through the soft magnetic core with substantially all of the successive domains of magnetic material having first and second surfaces, the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- the second surface conforms to the shape of the domains of metal material that the second surface has progressed from with a majority of the domains in the successive domains of metal material having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- the electrical device may be an electric motor coupled to a power source, the electric motor having a frame with a rotor and a stator coupled to the frame.
- either the rotor or the stator may have a winding coupled to the power source and a soft magnetic core with the winding wound about a portion of the soft magnetic core.
- the soft magnetic core may have a plurality of domains of magnetic material, each of the domains of the plurality of domains of magnetic material substantially separated by a layer of high resistivity insulating material as disclosed herein.
- any suitable electrical device that has a soft magnetic core with material as disclosed herein may be provided.
- FIG. 24 there is shown an exploded isometric view of brushless motor 800.
- Motor 800 is shown having rotor 802, stator 804 and housing 806.
- Housing 806 may have position sensor or hall elements 808.
- Stator 804 may have windings 810 and stator core 812.
- Rotor 802 may have rotor core 814 and magnets 816.
- stator core 812 and/or rotor core 814 may be fabricated from the material and methods discussed above having insulated domains and the methods thereof disclosed above.
- FIG. 25 there is shown a schematic view of brushless motor 820.
- Motor 820 is shown having rotor 822, stator 824 and base 826.
- Motor 820 may also be an induction motor, a stepper motor or similar type motor.
- Housing 827 may have position sensor or hall elements 828.
- Stator 824 may have windings 830 and stator core 832.
- Rotor 822 may have rotor core 834 and magnets 836.
- stator core 832 and/or rotor core 834 may be fabricated from the disclosed materials and/or by the methods discussed above.
- stator core 832 and/or rotor core 834 may be fabricated either completely or in part from bulk material such as material 32, 332, 512, 648, 700 and as discussed above where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of motor 820 may be made from such material and where motor 820 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- Linear motor 850 has primary 852 and secondary 854.
- Primary 852 has primary core 862 and windings 856, 858, 860.
- Secondary 854 has secondary plate 864 and permanent magnets 866.
- primary core 862 and/or secondary plate 864 may be fabricated from the materials and/or by the disclosed methods disclosed herein.
- primary core 862 and/or secondary plate 864 may be fabricated either completely or in part from bulk material, such as material 32, 332, 512, 648, 700 and as disclosed herein where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of motor 850 may be made from such material and where motor 850 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- any portion of motor 870 may be made from such material and where motor 870 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- FIG. 27 there is shown an exploded isometric view of electric generator 890.
- Generator or alternator 890 is shown having rotor 892, stator 894 and frame or housing 896.
- Housing 896 may have brushes 898.
- Stator 894 may have windings 900 and stator core 902.
- Rotor 892 may have rotor core 895 and windings 906.
- stator core 902 and/or rotor core 895 may be fabricated from the disclosed materials and / or by the disclosed methods.
- FIG. 28 there is shown a cutaway isometric view of stepping motor 910.
- Motor 910 is shown having rotor 912, stator 914 and housing 916.
- Housing 916 may have bearings 918.
- Stator 914 may have windings 920 and stator core 922.
- Rotor 912 may have rotor cups 924 and permanent magnet 926.
- stator core 922 and/or rotor cups 924 may be fabricated from the disclosed materials and/or by the disclosed methods.
- stator core 922 and/or rotor cups 924 may be fabricated either completely or in part from bulk material such as material 32, 332, 512, 648, 700 and as described where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of motor 890 may be made from such material and where motor 890 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- FIG. 29 there is shown an exploded isometric view of an AC motor 930.
- Motor 930 is shown having rotor 932, stator 934 and housing 936.
- Housing 936 may have bearings 938.
- Stator 934 may have windings 940 and stator core 942.
- Rotor 932 may have rotor core 944 and windings 946.
- stator core 942 and/or rotor core 944 may be fabricated from the disclosed materials and/or by the disclosed methods.
- stator core 942 and/or rotor core 944 may be fabricated either completely or in part from bulk material such as material 32, 332, 512, 648, 700 and as described where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of motor 930 may be made from such material and where motor 930 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- Transformer 970 is shown having core 972 and coil or windings 974.
- core 972 may be fabricated either completely or in part from bulk material such as material 32, 332, 512, 648, 700 and as described where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of transformer 970 may be made from such material and where transformer 970 may be any suitable transformer or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- Transformer 980 is shown having oil filled housing 982, radiator 984, core 986 and coil or windings 988.
- core 986 may be fabricated either completely or in part from bulk material such as material 32, 332, 512, 648, 700 and as described where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of transformer 980 may be made from such material and where transformer 980 may be any suitable transformer or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- solenoid 1000 there is shown a schematic view of solenoid 1000.
- Solenoid 1000 is shown having plunger 1002, coil or winding 1004 and core 1006.
- core 1006 and/or plunger 1002 may be fabricated either completely or in part from bulk material such as material 32, 332, 512, 648, 700 and as described where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of solenoid 1000 may be made from such material and where solenoid 1000 may be any suitable solenoid or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- FIG. 35 there is shown a schematic view of an inductor 1020.
- Inductor 1020 is shown having coil or winding 1024 and core 1026.
- core 1026 may be fabricated either completely or in part from bulk material such as material 32, 332, 512, 648, 700 and as described where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of inductor 1020 may be made from such material and where inductor 1020 may be any suitable inductor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- Fig. 36 is a schematic view of a relay or contactor 1030.
- Relay 1030 is shown having core 1032, coil or winding 1034, spring 1036, armature 1038 and contacts 1040.
- core 1032 and/or armature 1038 may be fabricated either completely or in part from bulk material such as material 32, 332, 512, 648, 700 and as described where the material is highly permeable magnetic material having domains of highly magnetically permeable material with insulating boundaries.
- any portion of relay 1030 may be made from such material and where relay 1030 may be any suitable relay or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries.
- 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.
- 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.
- 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.
- 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.
- the reactive gas may be oxygen or air where an oxide is grown on the surface of particles 1118 being deposited while in flight.
- 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.
- 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.
- 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 Fig's. 39 and 40 respectively.
- 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.
- the mask is shown moveable relative to the support.
- the support may be shown moveable relative to the mask.
- the mask and support is shown moveable relative to the deposition device.
- the deposition device may be moveable relative to the support and mask.
- Shape 1110 is shown with uniform cross section.
- 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.
- the mask m1124, 1126 ay 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.
- a cross section of a bulk material 1200 there is shown a cross section of a bulk material 1200.
- 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.
- heat 1220 is 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.
- 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.
- other materials for example, other than iron or other than iron oxide or other than aluminum may be provided.
- the powder may be Fe, FeSi, FeSiAl, FeAl or any suitable material.
- the iron particles may be pre coated with a different material.
- 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.
- a method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material 1210 and a non-magnetic material 1214 wherein the magnetic material comprises coated iron particles is provided by providing a reservoir adapted to contain the soft magnetic bulk material of the predetermined shape as will be described.
- a heat source 1220 is provided for heating the magnetic material and the non-magnetic material in the reservoir to an ignition temperature of a thermite reaction thus forming the soft magnetic bulk material of a predetermined shape.
- 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.
- iron particles with iron oxide coating are provided within reservoir 1262.
- support or piston 1270 may be heated, for example, to facilitate the reaction or stress relieve part 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.
- the powder 1262 may be iron oxide coated iron particles
- the heat source 1274 may be a switchable laser
- the alternative powder source 1276 may be a switchable, via metering valve 1282, pressurized stream of aluminum powder 1286.
- 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.
- 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.
- 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.
- 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 .
- 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.
- iron particles with iron oxide coating are provided within reservoir powder source 1314 and aluminum powder is provided within powder source 1316.
- support 1310 may be heated, for example, to facilitate the reaction or stress relieve part 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.
- 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.
- scanner 1318 may not be provided, for example, where an x-y scanner or indexer is coupled to support 1310.
- 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
- the alternative powder source 1316 may be a switchable, via metering valve 1328, pressurized stream of aluminum powder 1324.
- 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.
- 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.
- 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.
- aluminum powder source 1316 may not be provided, for example, where the aluminum powder is mixed with the iron powder in source 1314.
- 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 Fig's. 23 A& B or otherwise as disclosed.
- 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.
- 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 Fig's 41 and 42.
- 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.
- 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.
- 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 Fig's 41 and 42.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Mechanical Engineering (AREA)
- Organic Chemistry (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Electromagnetism (AREA)
- Dispersion Chemistry (AREA)
- Soft Magnetic Materials (AREA)
- Manufacture Of Motors, Generators (AREA)
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
- Powder Metallurgy (AREA)
- Magnetic Heads (AREA)
Description
- The disclosed embodiment relates to system and method for making a structured material and more particularly making a material having domains with insulated boundaries.
- Electric machines, such as DC brushless motors, and the like, may be used in an increasing variety of industries and applications where a high motor output, superior efficiency of operation, and low manufacturing cost often play a critical role in the success and environmental impact of the product, e.g., robotics, industrial automation, electric vehicles, HVAC systems, appliances, power tools, medical devices, and military and space exploration applications. These electric machines typically operate at frequencies of several hundred Hz with relatively high iron losses in their stator winding cores and often suffer from design limitations associated with the construction of stator winding cores from laminated electrical steel.
- A typical brushless DC motor includes a rotor, with a set of permanent magnets with alternating polarity, and a stator. The stator typically comprises a set of windings and a stator core. The stator core is a key component of the magnetic circuit of the motor as it provides a magnetic path through the windings of the motor stator.
- In order to achieve high efficiency of operation, the stator core needs to provide a good magnetic path, i.e., high permeability, low coercivity and high saturation induction, while minimizing losses associated with eddy currents induced in the stator core due to rapid changes of the magnetic field as the motor rotates. This may be achieved by constructing the stator core by stacking a number of individually laminated thin sheet-metal elements to build the stator core of the desired thickness. Each of the elements may be stamped or cut from sheet metal and coated with insulating layer that prevents electric conduction between neighboring elements. The elements are typically oriented in such a manner that magnetic flux is channeled along the elements without crossing the insulation layers which may act as air gaps and reduce the efficiency of the motor. At the same time, the insulation layers prevent electric currents perpendicular to the direction of the magnetic flux to effectively reduce losses associated with eddy currents induced in the stator core.
- The fabrication of a conventional laminated stator core is complicated, wasteful, and labor intensive because the individual elements need to be cut, coated with an insulating layer and then assembled together. Furthermore, because the magnetic flux needs to remain aligned with the laminations of the iron core, the geometry of the motor may be considerably constrained. This typically results in motor designs with sub-optimal stator core properties, restricted magnetic circuit configurations, and limited cogging reduction measures critical for numerous vibration-sensitive applications, such as in substrate-handling and medical robotics, and the like. It may also be difficult to incorporate cooling into the laminated stator core to allow for increased current density in the windings and improve the torque output of the motor. This may result in motor designs with sub-optimal properties.
- 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.
- "In Situ Formation of Particle Reinforced Al Matrix Composite by Selective Laser melting of Al/Fe203 Powder Mixture" by Sasan Dadbakhsh and Liang Hao in Advance Engineering Materials vol. 14 No. 1-2, is background art.
- The invention is defined in
independent claim 1. Further aspects and preferred embodiments are defined in the dependent claims. Any aspects, embodiments and examples of the present disclosure which do not fall under the scope of the appended claims do not form part of the invention and are merely provided for illustrative purposes. - A system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface and a gas subsystem configured to introduce one or more reactive gases to an area proximate in-flight droplets. The one or more reactive gases create an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.
- The droplet spray subsystem may include a crucible configured to create the molten metal alloy direct the molten alloy droplets towards the surface. The droplet spray subsystem may include a wire arc droplet deposition subsystem configured to create the molten metal alloy droplets and direct the molten alloy droplets towards the surface. The droplet subsystem includes one or more of: a plasma spray droplet deposition subsystem, a detonation spray droplet deposition subsystem, a flame spray droplet deposition subsystem, a high velocity oxygen fuel spray (HVOF) droplet deposition subsystem, a warm spray droplet deposition subsystem, a cold spray droplet deposition subsystem, and a wire arc droplet deposition subsystem each configured to form the metal alloy droplets and direct the alloy droplets towards the surface. The gas subsystem may include a spray chamber having one or more ports configured to introduce the one or more reactive gases to the proximate the in-flight droplets. The gas subsystem may include a nozzle configured to introduce the one or more reactive gases to the in-flight droplets. The surface may be movable. The system may include a mold on the surface configured to receive the droplets and form the material having domains with insulated boundaries in the shape of the mold. The droplet spray subsystem may include a uniform droplet spray subsystem configured to generate the droplets having a uniform diameter. The system may include a spray subsystem configured to introduce an agent proximate in-flight droplets to further improve the properties of the material. The one or more gases may include reactive atmosphere. The system may include a stage configured to move the surface location in one or more predetermined directions.
- In accordance with another aspect of the disclosed embodiment, a system for making a material having domains with insulated boundaries is provided. The system includes a spray chamber, a droplet spray subsystem coupled to the spray chamber configured to create molten alloy droplets and direct the molten alloy droplets to a predetermined location in the spray chamber and a gas subsystem configured to introduce one or more reactive gases into the spray chamber. The one or more reactive gases create an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.
- In accordance with another aspect of the disclosed embodiment, a system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface and a spray subsystem configured to introduce an agent proximate in-flight droplets. Wherein the agent creates an insulation layer on the droplets in flight such that said droplets form a material having domains with insulated boundaries on the surface.
- In accordance with another aspect of the disclosed embodiment, a system for making a material having domains with insulated boundaries is provided. The system includes a spray chamber, a droplet spray subsystem coupled to the spray chamber configured to create molten alloy droplets and direct the molten alloy droplets to a predetermined location in the spray chamber and a spray subsystem coupled to the spray chamber configured to introduce an agent. The agent creates an insulation layer on said droplets in flight such that said droplets form a material having domains with insulated boundaries on the surface.
- In accordance with another aspect of the disclosed embodiment, a method for making a material having domains with insulated boundaries is provided. The method includes creating molten alloy droplets, directing the molten alloy droplets to a surface, and introducing one or more reactive gases proximate in-flight droplets such that the one or more reactive gases creates an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.
- The method may include the step of moving the surface in one or more predetermined directions. The step of introducing molten alloy droplets may include introducing molten alloy droplets having a uniform diameter. The method may include the step of introducing an agent proximate in-flight droplets to improve the properties of the material.
- In accordance with another aspect of the disclosed embodiment, a method for making a material having domains with insulated boundaries is provided. The method includes creating molten alloy droplets, directing the molten alloy droplets to a surface, and introducing an agent proximate the in-flight droplets to create an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.
- In accordance with another aspect of the disclosed embodiment, a method for making a material having domains with insulated boundaries is provided. The method includes creating molten alloy droplets, introducing molten alloy droplets into a spray chamber, directing the molten alloy droplets to a predetermined location in the spray chamber, and introducing one or more reactive gases into the chamber such that the one or more reactive gases creates an insulation layer on the droplets in flight so that the droplets form a material having domains with insulated boundaries.
- In accordance with another aspect of the disclosed embodiment, a material having domains with insulated boundaries is provided. The material includes a plurality of domains formed from molten alloy droplets having an insulation layer thereon and insulation boundaries between the domains.
- In accordance with one aspect of the disclosed embodiment, a system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface and a spray subsystem configured to direct a spray of an agent at deposited droplets on the surface. The agent creates insulation layers on the deposited droplets such that the droplets form a material having domains with insulated boundaries on the surface.
- The agent may directly form the insulation layers on the deposited droplets to form the material having domains with insulated boundaries on the surface. The spray of agent may facilitate and/or participate and/or accelerate a chemical reaction that forms insulation layers on the deposited droplets to form the material having domains with insulated boundaries. The droplet spray subsystem may include a crucible configured to create the molten metal alloy direct the molten alloy droplets towards the surface. The droplet spray subsystem may include a wire arc droplet deposition subsystem configured to create the molten metal alloy droplets and direct the molten alloy droplets towards the surface. The droplet subsystem may include one or more of: a plasma spray droplet deposition subsystem, a detonation spray droplet depositions subsystem, a flame spray droplet deposition subsystem, a high velocity oxygen fuel spray (HVOF) droplet deposition subsystem, a warm spray droplet deposition subsystem, a cold spray droplet deposition subsystem, and a wire arc droplet deposition subsystem, each configured to form the metal alloy droplets and direct the alloy droplets towards the surface. The spray subsystem may include one or more nozzles configured to direct the agent at the deposited droplets. The spray subsystem may include a spray chamber having one or more ports coupled to the one or more nozzles. The droplet spray subsystem may include a uniform droplet spray subsystem configured to generate the droplets having a uniform diameter. The surface may be movable. The system may include a mold on the surface to receive the deposited droplets and form the material having domains with insulated boundaries in the shape of the mold. The system may include a stage configured to move the surface in one or more predetermined directions. The system may include a stage configured to move the mold in one or more predetermined directions.
- In accordance with another aspect of the disclosed embodiment, a system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create and eject molten alloy droplets into a spray chamber and direct the molten alloy droplets to a predetermined location in the spray chamber. The spray chamber is configured to maintain a predetermined gas mixture which facilitates and/or participates and/or accelerates in a chemical reaction that forms an insulation layer with deposited droplets to form a material having domains with insulated boundaries.
- In accordance with another aspect of the disclosed embodiment, a system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem including at least one nozzle. The droplet spray subsystem is configured to create and eject molten alloy droplets into one or more spray sub-chambers and direct the molten alloy droplets to a predetermined location in the one or more spray sub-chambers. One of the one or more spray sub-chambers is configured to maintain a first predetermined pressure and gas mixture therein which prevents a reaction of the gas mixture with the molten alloy droplets and the nozzle and the other of the one or more sub-chambers is configured to maintain a second predetermined pressure and gas mixture which facilitates and/or precipitates and/or accelerates in a chemical reaction that forms an insulation layer on deposited droplets to form a material having domains with insulated boundaries.
- In accordance with another aspect of the disclosed embodiment, a method for making a material having domains with insulated boundaries is provided. The method includes creating molten alloy droplets, directing the molten alloy droplets to a surface and directing an agent at deposited droplets such that the agent creates a material having domains with insulated boundaries.
- The spray of agent may directly create insulation layers on the deposited droplets to form the material having domains with insulated boundaries. The spray of agent may facilitate and/or participate and/or accelerate a chemical reaction that form insulation layers on the deposited droplets to form the material having domains with insulated boundaries.
- In accordance with another aspect of the disclosed embodiment, a method of making a material having domains with insulated boundaries is provided. The method includes creating molten alloy droplets, directing the molten alloy droplets to a surface inside a spray chamber, and maintaining a predetermined gas mixture in the spray chamber which facilitates and/or precipitates and/or accelerates in a chemical reaction to form an insulation layer on the deposited droplets to form a material having domains with insulated boundaries.
- In accordance with another aspect of the disclosed embodiment, a method for making a material having domains with insulated boundaries is provided. The method includes creating molten alloy droplets, directing the molten alloy droplets with a nozzle to a surface in one or more spray sub-chambers, maintaining a first predetermined pressure and gas mixture in one of the spray chambers which prevents a reaction of the gas mixture with molten alloy droplets and the spray nozzle, and maintaining a second predetermined pressure and gas mixture in the other of the spray sub-chamber which facilitates and/or precipitates and/or accelerates a chemical reaction that forms an insulation layer on deposited droplets to form a material having domains with insulated boundaries.
- In accordance with another aspect of the disclosed embodiment, a material having domains with insulated boundaries is provided. The material includes a plurality of domains formed from molten alloy droplets having an insulation layer thereon and insulation boundaries between said domains.
- In accordance with another aspect of the disclosed embodiment, a system for making a material having domains with insulated boundaries is provided. The system includes a combustion chamber, a gas inlet configured to inject a gas into the combustion chamber, a fuel inlet configured to inject a fuel into the combustion chamber, an igniter subsystem configured to ignite a mixture of the gas and the fuel to create a predetermined temperature and pressure in the combustion chamber, a metal powder inlet configured to inject a metal powder comprised of particles coated with an electrically insulating material into the combustion, wherein the predetermined temperature creates conditioned droplets comprised of the metal powder in the chamber, and an outlet configured to eject and accelerate combustion gases and the conditioned droplets from the combustion chamber and towards a stage such that conditioned droplets adhere to the stage to form a material having domains with insulated boundaries thereon.
- The particles of the metal powder may include an inner core made of a soft magnetic material and an outer layer made of the electrically insulating material. The conditioned droplets may include a solid outer core and a softened and/or partially melted inner core. The outlet may be configured to eject and accelerate the combustion gases and the conditioned droplets from the combustion chamber at a predetermined speed. The particles may have a predetermined size. The stage may be configured to move in one or more predetermined directions. The system may include a mold on the stage to receive the conditioned droplets and form the material having domains with insulated boundaries in the shape of the mold. The stage may be configured to move in one or more predetermined directions.
- In accordance with another aspect of the disclosed embodiment, a method for making a material having domains with insulated boundaries is provided. The method includes creating conditioned droplets from a metal powder made of metal particles coated with an electrically insulating material at a predetermined temperature and pressure and directing the conditioned droplets at a stage such that the conditioned droplets create material having domains with insulated boundaries thereon.
- The particles of the metal powder may include an inner core made of a soft magnetic material and outer layer made of the electrically insulating material and the step of creating conditioned droplets includes the step of softening and partially melting the inner core while providing a solid outer core. The conditioned droplets may be directed at the stage at a predetermined speed. The method may include the step of moving the stage in one or more predetermined directions. The method may include the step of providing a mold on the stage.
- In accordance with another aspect of the disclosed embodiment, a system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material is provided. The system includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material. The heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on to the support to form the bulk material having insulated boundaries.
- The source of insulating material may comprise a reactive chemical source and the deposition device may deposit the particles of the metal material in the softened or molten state on the support in a deposition path such that insulating boundaries are formed on the metal 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 metal material by the coating device from a chemical reaction of the reactive chemical source after the deposition device deposits the particles of the metal material in the softened or molten state on to the support. The source of insulating material may comprise a reactive chemical source and the coating device may coat the metal 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 deposition device may comprise a uniform droplet spray deposition device. The source of insulating material may comprise a reactive chemical source and the coating device may coat the metal 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 metal material with the insulating material 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 metal material with the insulating material to form insulating boundaries formed from co-spraying of the insulating material. The coating device may coat the metal material with the insulating material to form insulating boundaries formed from a chemical reaction and a coating from the source of insulating material. The bulk material may include domains formed from the metal material with insulating boundaries. The softened or molten state may be at a temperature below the melting point of the metal material. The deposition device may deposit the particles simultaneously while the coating device coats the metal material from the source of the insulating material. The coating device may coat the metal material with the insulating material after the deposition device deposits the particles.
- In accordance with another aspect of the disclosed embodiment, a system for forming a soft magnetic bulk material from a magnetic material and a source of an insulating material is provided. The system includes a heating device coupled to the support and a deposition device coupled to the support, a support configured to support the soft magnetic bulk material. The heating device heats the magnetic material to form particles having a softened state and the deposition device deposits particles of the magnetic material in the softened state on the support to form the soft magnetic bulk material and the soft magnetic bulk material has domains formed from the magnetic material with insulating boundaries formed from the source of insulating material.
- 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 formed 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.
- In accordance with another aspect of the disclosed embodiment, a system for forming a soft magnetic bulk material from a magnetic material and a source of insulating material is provided. The system includes a heating device, a deposition device, a coating device and a support configured to support the soft magnetic bulk material. The heating device heats the magnetic material to form particles having a softened or molten state and the coating device coats the magnetic material with the source of insulating material from the source and the deposition device deposits particles of the magnetic material in the softened or molten state on to the support to form the soft magnetic bulk material having insulated boundaries.
- 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.
- Providing the source of insulating material may include providing a reactive chemical source and particles of the metal material in the softened state may be deposited on the support in a deposition path and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source in the deposition path. Providing the source of insulating material may include providing a reactive chemical source and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source after the depositing the particles of the metal material in the softened state on to the support. The method may include setting the molten state at a temperature above the melting point of the metal material. Providing the source of insulating material may include providing a reactive chemical source and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source at the surface of the particles. Depositing particles may include uniformly depositing the particles on the support. Providing the source of insulating material may include providing a reactive chemical source and the insulating boundaries may be formed from a chemical reaction of the reactive chemical source in a reactive atmosphere. Providing the source of insulating material may include providing 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 co-spraying of the agent. The method may include forming the insulating boundaries by co-spraying the insulating material. The method may include forming the insulating boundaries 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 metal material. The method may include coating the metal material with the insulating material. The particles may comprise the metal material coated with the insulating material. The particles may comprise coated particles of metal material coated with the insulating material and heating the material may include heating the coated particles of metal material coating with insulation boundaries. The method may include coating the metal material with the insulating material simultaneously while depositing the particles. The method may include coating the metal material with the insulating material after depositing the particles. The method may include annealing the bulk metal material. The method may include heating the bulk metal material simultaneously while depositing the particles.
- In accordance with one aspect of the disclosed embodiment, a method of forming a soft magnetic bulk material is provided. The method includes providing a magnetic material, providing a source of insulating material, providing a support configured to support the soft magnetic bulk material, heating the magnetic material to a softened state, and depositing particles of the magnetic material in the softened state on to support to form the soft magnetic bulk material having domains formed from the magnetic material with insulating boundaries.
- In accordance with one aspect of the disclosed embodiment, a bulk material formed on a surface is provided. The bulk material includes a plurality of adhered domains of metal material, substantially all of the domains of the plurality of domains of metal material separated by a predetermined layer of high resistivity insulating material. A first portion of the plurality of domains forms a surface. A second portion of the plurality of domains includes successive domains of metal material progressing from the first portion, substantially all of the domains in the successive domains each include a first surface and second surface, the first surface opposing the second surface, the second surface conforming to a shape of progressed domains, and a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- The layer of high resistivity insulating material may include a material having a resistivity greater than about 1×103 Ω-m. The layer of high resistivity insulating material may have a selectable substantially uniform thickness. The metal material may comprise a ferromagnetic material. The layer of high resistivity insulating material may comprise ceramic. The first surface and the second surface may form an entire surface of the domain. The first surface may progress in a substantially uniform direction from the first portion.
- In accordance with one aspect of the disclosed embodiment, a soft magnetic bulk material formed on a surface is provided. The soft magnetic bulk material includes a plurality of domains of magnetic material, each of the domains of the plurality of domains of magnetic material substantially separated by a selectable coating of high resistivity insulating material. A first portion of the plurality of domains forms a surface. A second portion of the plurality of domains includes successive domains of magnetic material progressing from the first portion, substantially all of the domains in the successive domains of magnetic material in the second portion each include a first surface and a second surface, the first surface comprising a substantially convex surface, and the second surface comprising one or more substantially concave surfaces.
- 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 more substantially concave surfaces.
- In accordance with another aspect of the disclosed embodiment, an electric motor coupled to a power source is provided. The electric motor includes a frame, a rotor coupled to the frame, a stator coupled to the frame, at least one of the rotor or the stator including a winding coupled to the power source and a soft magnetic core. The winding is wound about a portion of the soft magnetic core. 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 include a first surface and a second surface, the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- In accordance with another aspect of the disclosed embodiment, a soft magnetic bulk material formed on a surface is provided. The soft magnetic bulk material includes a plurality of adhered domains of magnetic material, substantially all of the domains of the plurality of domains of magnetic material separated by a layer of high resistivity insulating material. A first portion of the plurality of domains forms a surface. A second portion of the plurality of domains includes successive domains of magnetic material progressing from the first portion, substantially all of the domains in the successive domains each including a first surface and a second surface, the first surface opposing the second surface, the second surface conforming to the shape of progressed domains. A majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- 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, each of the domains of the plurality of domains substantially separated by a layer of high resistivity insulating material. The plurality of domains include successive domains of magnetic material progressing through the soft magnetic core. Substantially all of the successive domains each include a first surface and a second surface, the first surface opposing the second surface, the second surface conforming to the shape of progressed domains of metal material, and a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.
- 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, each of the domains of the plurality of domains substantially separated by a layer of high resistivity insulating material. The plurality of domains include successive domains of magnetic material progressing through the soft magnetic core. Substantially all of the successive domains each include a first surface and a second surface, the first surface opposing the second surface, the second surface conforming to the shape of progressed domains of metal material, and a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more 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.
- Other objects, features and advantages will occur to those skilled in the art from the following description of an embodiment and the accompanying drawings, in which:
-
Fig. 1 is a schematic block diagram showing the primary components of one embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 2 is a schematic side-view showing another embodiment of the droplet spray subsystem in a controlled atmosphere; -
Fig. 3 is a schematic side-view showing another embodiment of the system and method for expediting production of a material having domains with insulated boundaries; -
Fig. 4 is a schematic side-view showing another embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 5A is a schematic diagram of one embodiment of the material having domains with insulated boundaries created using the system and method of one or more embodiments; -
Fig. 5B is a schematic diagram of another embodiment of the material having domains with insulated boundaries created using the system and method of one or more embodiments; -
Fig. 6 is a schematic block diagram showing the primary components of another embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 7 is a schematic block diagram showing the primary components of another embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 8 is a schematic block diagram showing the primary components of one embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 9 is a side-view showing one example of the formation of a material having domains with insulated boundaries associated with the system shown inFig. 8 ; -
Fig. 10A is a schematic diagram of one embodiment of the material having domains with insulated boundaries created using the system and method of one or more embodiments; -
Fig. 10B is a schematic diagram of another embodiment of the material having domains with insulated boundaries created using the system and method of one or more embodiments; -
Fig. 11 is a side-view showing one example of the formation of a material having domains with insulated boundaries associated with the system shown inFig. 8 ; -
Fig. 12 is a side-view showing one example of the formation of a material having domains with insulated boundaries associated with the system shown inFig. 8 ; -
Fig. 13 is a schematic block diagram showing the primary components of another embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 14 is a side-view showing one example of the formation of a material having domains with insulated boundaries associated with the system shown inFig. 13 ; -
Fig. 15 is a schematic block diagram showing the primary components of yet another embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 16 is schematic top-view showing one example of the discrete deposition process of droplets associated with the system shown in one or more ofFigs. 8-15 ; -
Fig. 17 is a schematic side-view showing one example of a nozzle for the system shown in one or more ofFigs. 8-15 which includes a plurality of orifices; -
Fig. 18 is a schematic side-view showing another embodiment of the droplet spray subsystem shown in one or more ofFigs. 8-15 ; -
Fig. 19 is a schematic block diagram showing the primary components of yet another embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 20 is a schematic block diagram showing the primary components of yet another embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 21 is a schematic block diagram showing the primary components of one embodiment of the system and method for making a material having domains with insulated boundaries; -
Fig. 22A is a schematic diagram showing in further detail the structured material having domains with insulated boundaries shown inFig 21 ; -
Fig. 22B is a schematic diagram showing in further detail the structured material having domains with insulated boundaries shown inFig 21 ; -
Fig. 23A is a schematic cross section view of one embodiment of a structured material; -
Fig. 23B is a schematic cross section view of one embodiment of a structured material; -
Fig. 24 is a schematic exploded isometric view of one embodiment of a brushless motor incorporating the structured material of the disclosed embodiment; -
Fig. 25 is a schematic top-view of one embodiment of a brushless motor incorporating the structured material of the disclosed embodiment; -
Fig. 26A is a schematic side-view of a linear motor incorporating the structured material of the disclosed embodiment; -
Fig. 26B is a schematic side-view of a linear motor incorporating the structured material of the disclosed embodiment; -
Fig. 27 is an exploded schematic isometric view of an electric generator incorporating the structured material of the disclosed embodiment; -
Fig. 28 is a three-dimensional cutaway isometric view of a stepping motor incorporating the structured material of the disclosed embodiment; -
Fig. 29 is a three-dimensional exploded isometric view of an AC motor incorporating the structured material of the disclosed embodiment; -
Fig. 30 is a three-dimensional cutaway isometric view of one embodiment of an acoustic speaker incorporating the structured material of the disclosed embodiment; -
Fig. 31 is a three-dimensional isometric view of a transformer incorporating the structured material of the disclosed embodiment; -
Fig. 32 is a three-dimensional cutaway isometric view of a power transformer incorporating the structured material of the disclosed embodiment; -
Fig. 33 is a schematic side-view of a power transformer incorporating the structured material of the disclosed embodiment; -
Fig. 34 is a schematic side-view of a solenoid incorporating the structured material of the disclosed embodiment; -
Fig. 35 is a schematic top-view of an inductor incorporating the structured material of the disclosed embodiment; -
Fig. 36 is a schematic side-view of a relay 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. - Aside from the embodiment disclosed below, the disclosed embodiment invention is capable of other embodiments and of being practiced or being carried out in various ways. Thus, it is to be understood that the disclosed embodiment is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. If only one embodiment is described herein, the claims hereof are not to be limited to that embodiment. Moreover, the claims hereof are not to be read restrictively unless there is clear and convincing evidence manifesting a certain exclusion, restriction, or disclaimer.
- There is shown in
Fig. 1 ,system 10 and the method thereof for making a material having domains with insulated boundaries.System 10 includesdroplet spray subsystem 12 configured to createmolten alloy droplets 16 and directmolten alloy droplets 16 towardssurface 20. In one design,droplet spray subsystem 12 directs molten alloy droplets intospray chamber 18. In an alternate aspect,spray chamber 18 is not required as will be discussed below. - In one embodiment,
droplet spray subsystem 12 includescrucible 14 which createsmolten alloy droplets 16 and directsmolten alloy droplets 16 towardssurface 20.Crucible 14 may includeheater 42 which formsmolten alloy 44 inchamber 46. The material used to makemolten alloy 44 may have a high permeability, low coercivity and high saturation induction.Molten alloy 44 may be made from a magnetically soft iron alloy, such as iron-base alloy, iron-cobalt alloy, nickel-iron alloy, silicon iron alloy, iron-aluminide, ferritic stainless steel, or similar type alloy.Chamber 46 may receiveinert gas 47 viaport 45.Molten alloy 44 may be ejected throughorifice 22 due to the pressure applied frominert gas 47 introduced viaport 45.Actuator 50 with vibration transmitter 51 may be used to vibrate a jet ofmolten alloy 44 at a specified frequency to break upmolten alloy 44 into stream ofdroplets 16 which are ejected throughorifice 22.Crucible 14 may also includetemperature sensor 48. Although as showncrucible 14 includes oneorifice 22, in alternate,crucible 14 may have any number oforifices 22 as needed to accommodate higher deposition rates ofdroplets 16 onsurface 20, e.g., up to 100 orifices or more. - Droplet spray subsystem 12',
Fig. 2 , where like parts have been given like numbers, includes wire arcdroplet deposition subsystem 250 which createsmolten alloy droplets 16 and directsmolten alloy droplets 16 towardssurface 20. Wire arcdroplet deposition subsystem 250 includeschamber 252 which houses positivewire arc wire 254 andnegative arc wire 256.Alloy 258 is preferably disposed in each ofwire arc wires Alloy 258 may be used to createdroplets 16 to be directed towardsurface 20 and may be composed mainly of iron (e.g., greater than about 98%) with very low amount of carbon, sulfur, and nitrogen content, (e.g., less than about 0.005%) and may include minute quantities of Cr (e.g., less than about 1%) with the balance, in this example, being Si or Al to achieve good magnetic properties. The metallurgical composition may be tuned to provide improvements in the final properties of the material having domains with insulated boundaries.Nozzle 260 may be configured to introduce one ormore gases gas 268 insidechamber 252.Pressure control valve 266 controls the flow of one or more ofgases chamber 252. In operation, the voltage applied topositive arc wire 254 andnegative arc wire 256 createsarc 270 which causesalloy 258 to formmolten alloy droplets 16 which are directed towardssurface 20. In one example, voltages between about 18 and 48 volts and currents between about 15 to 400 amperes may applied topositive wire arc 254 andnegative arc wire 256 to provide a continuous wire arc spray process ofdroplets 16. In this example,system 10 includesspray chamber 16. - System 10',
Fig. 3 , where like parts have been given like numbers, includesdroplet spray subsystem 12" with wire arc droplet deposition subsystem 250' that createsmolten alloy droplets 16 and directsmolten alloy droplets 16 towardssurface 20. Here, system 10' does not includechamber 252,Fig. 2 , andchamber 18,Figs. 1 and 2 . Instead,nozzle 260,Fig. 3 , may be configured to introduce one ormore gases gas 268 in the area proximatepositive arc wire 254 andnegative arc wire 256. Similar as discussed above with reference toFig. 2 , the voltage applied topositive arc wire 254 andnegative arc wire 256 createsarc 270 which causesalloy 258 to formmolten alloy droplets 16 which are directed towardssurface 20. Reactive gas 26 (discussed below) is introduced to the area proximate in-flightmolten alloy droplets 16, e.g., usingnozzle 263.Shroud 261 may be used to containreactive gas 26 anddroplets 16 in the areaproximate surface 20. -
System 10",Fig. 4 , where like parts have been given like numbers, may include dropletspray deposition subsystem 12‴ having wire arcdroplet deposition subsystem 250" having a plurality ofpositive arc wire 254,negative arc wires 256 andnozzles 260 which may be used simultaneously to achieve higher spray deposition rates ofmolten alloy droplets 16 onsurface 20. Wire arcs 254, 256, and similar deposition devices discussed above, may be provided in different directions to form the material having domains of insulated boundaries. Wire arcdroplet deposition subsystem 250" is not enclosed in a chamber. In an alternate aspect,wire arc spray 250" may be enclosed in chamber, e.g.,chamber 252,Fig. 2 . When a chamber is not used,shroud 261,Fig. 4 , may be used to containreactive gas 26 anddroplets 16 in the areaproximate surface 20. - In alternate aspects,
droplet spray subsystem 12,Figs. 1-4 , may utilize a plasma spray droplet deposition subsystem, a detonation spray droplet deposition subsystem, a flame spray droplet deposition subsystem, a high velocity oxy-fuel spray (HVOF) droplet deposition subsystem, a warm spray droplet deposition subsystem, a cold spray droplet deposition subsystem, or any similar type spray droplet deposition subsystems. Accordingly, any suitable deposition system may be used in accordance with one or more of disclosed embodiments discussed above. -
Droplet spray subsystem 12,Figs. 1-4 , may be mounted on a single or plurality of robotic arms and/or mechanical arrangements so as to improve part quality, reduce spray time, and improve process economics. The subsystems may spraydroplets 16 simultaneously at the same approximate location or may be staggered so as the spray a certain location in a sequential manner.Droplet spray subsystem 12 may be controlled and facilitated by controlling one or more of the following spray parameters: wire speed, gas pressure, shroud gas pressure, spraying distance, voltage, current, speed of substrate motion, and/or the speed of arc tool movement. -
System 10,Figs. 1 and 2 , also may includeport 24 coupled tospray chamber 18 configured to introducegas 26, e.g., reactive atmosphere, intospray chamber 28.System 10', 10",Figs. 3 and 4 , may introducegas 26, e.g., reactive atmosphere, in the areaproximate droplets 16 in flight.Gas 26 may be chosen such that it creates an insulation layer ondroplets 16 as they are in flight towardssurface 20. A mixture of gases, one or more of which may participate in the reaction withdroplets 16, may be introduced to the areaproximate droplets 16 in flight.Caption 28,Fig. 1 , shows an example ofinsulation layer 30 being formed on in-flightmolten alloy droplets 16,Figs. 1-4 , during their flight to surface 20. Whendroplets 16 withinsulation layer 30 land onsurface 20 they form the beginning ofmaterial 32 having domains with insulated boundaries. Thereafter,subsequent droplets 16 withinsulation layer 30 land on the previously formedmaterial 32. In one aspect of the disclosed embodiment,surface 20 is moveable, e.g., usingstage 40, which may be an X-Y stage, a turn table, a stage that can additionally change the pitch and roll angle ofsurface 20, or any other suitable arrangement that can supportmaterial 32 and/or movematerial 32 in a controlled manner as it is formed.System 10 may include a mold (not shown) that is placed onsurface 20 to creatematerial 32 having any desired shape as known by those skilled in the art. -
Fig. 5A shows an example ofmaterial 32 that includesdomains 34 withinsulated boundaries 36 therebetween.Insulated boundaries 36 are formed from the insulation layer ondroplets 16, e.g.,insulation layer 30,Fig. 1 .Material 32,Fig 5A , may includeboundaries 36 between neighboringdomains 34 which are virtually perfectly formed as shown. In other aspects of the disclosed embodiment,material 32,Fig. 5B , may includeboundaries 36 between neighboringdomains 34 with discontinuities as shown.Material 32,Figs. 5A and 5B , reduces eddy current losses, and discontinuities inboundaries 36 between neighboringdomains 34 improve the mechanical properties ofmaterial 32. The result is thatmaterial 32 may preserve a high permeability, a low coercivity and a high saturation induction of the alloy. Here,boundaries 36 limit electrical conductivity between neighboringdomains 34.Material 32 provides a superior magnetic path due to its permeability, coercivity and saturation characteristics. The limited electrical conductivity ofmaterial 32 minimizes eddy current losses associated with rapid changes of the magnetic field, e.g., as a motor rotates.System 10 and the method thereof may be a single step, fully automated process which saves time and money and produces virtually no waste. In alternate aspects of the disclosed embodiment,system 10 may be operated manually, semi automatically or otherwise. -
System 10"',Fig. 6 , where like parts include like numbers, may also includespray subsystem 60 which includes at least one port, e.g.,port 62 and/orport 63, which is configured to introduceagent 64 intospray chamber 18.Spray subsystem 60 createsspray 66 and/orspray 67 ofspray agent 64 which coatsdroplets 16 having insulation layers thereon, e.g., insulation layers 30,Fig. 1 , withagent 64,Fig. 3 , whiledroplets 16 are in flight towardsurface 20.Agent 64 preferably may stimulate a chemical reaction that formsinsulation layer 30 and/or coat the particle to forminsulation layer 30; or a combination thereof, which may take place either simultaneously or sequentially. In a similar manner, system 10',Fig. 3 , andsystem 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 insulatingcoating 30.Agent 64 providesmaterial 32 with additional insulating capabilities.Agent 64 preferably may stimulate the chemical reaction that formsinsulation layer 30; may coat the particle to forminsulation layer 30; or a combination thereof which may take place either simultaneously or sequentially. -
System 10,Figs. 1, 2 , and6 may include chargingplate 70,Fig. 6 , coupled toDC source 72. Chargingplate 70 creates an electric charge ondroplets 16 to control their trajectory towardssurface 20. Preferably, coils (not shown) may be used to control the trajectory ofdroplets 16. Chargingplate 70 may be utilized in some applications to electrically chargedroplets 16 so that they repel each other and do not merge with each other. -
System 10,Figs. 1, 2 and6 , may includegas exhaust port 100,Fig. 6 .Exhaust port 100 may be used to expelexcessive gas 26 introduced byport 24 and/orexcessive agent 64 introduced byspray subsystem 60. In addition, as certain gases in gas 26 (e.g., reactive atmosphere) are likely to be consumed,exhaust port 100 allowsgas 26 to be replaced inspray chamber 18 in a controlled manner. Similarly, system 10',Fig. 3 , andsystem 10",Fig. 4 , may also include a gas exhaust port. -
System 10,Figs. 1, 2 , and6 , may includepressure sensor 102 insidechamber 46,Fig. 1 orchamber 252,Fig. 2 .System 10,Figs. 1, 2 , and6 , may also includepressure sensor 104,Fig. 2 insidespray chamber 18 and/ordifferential pressure sensor 106,Figs. 1, 2 , and6 betweencrucible 14 andspray chamber 18 and/ordifferential pressure sensor 106,Fig. 2 , betweenchamber 252 andspray chamber 18. The information about the pressure difference provided bysensors inert gas 47,Figs. 1 and6 , tocrucible 14 and the supply ofgas 26 into thespray chamber 18 or the supply ofgas Fig. 2 , tochamber 252. The difference in the pressures may serve as a way of controlling the ejection rate ofmolten alloy 44 throughorifice 20. In one design,controllable valve 108,Fig. 6 , coupled toport 45 may be utilized to control the flow of inert gas intochamber 46. Similarly,control valve 266 may be used to control the flow ofgases chamber 252.Controllable valve 110,Figs. 1, 2 , and6 , coupled toport 24 may be utilized to control the flow ofgas 26 intospray chamber 18. A flow meter (not shown) may also be coupled toport 24 to measure the flow rate ofgas 26 intospray chamber 18. -
System 10,Figs. 1, 2 , and6 , may also include a controller (not shown) that may utilize the measurements from thesensors port 24 to adjust thecontrollable valves chamber 46 andspray chamber 18 orchamber 252 andspray chamber 18 and the desired flow ofgas 26 intospray chamber 18. The controller may utilize the measurements fromtemperature sensor 48 incrucible 14 to adjust operation ofheater 42 to achieve/maintain the desired temperature ofmolten alloy 44. The controller may also control the frequency (and possibly amplitude) of the force produced byactuator 50,Fig. 1 , of the vibration transmitter 51 in thecrucible 14. -
System 10,Figs. 1, 2 , and6 may include a device for measuring the temperature of the depositeddroplets 16 onmaterial 32 and a device for controlling the temperature of the deposited droplets onmaterial 32. -
System 10",Fig. 7 , where like parts include like numbers, may includespray subsystem 60 which includes at least one port, e.g.,port 62 and/orport 63, which is configured to introduceagent 80 intospray chamber 18. Here, a reactive gas may not be utilized.Spray subsystem 60 createsspray 86 and/orspray 87 ofspray agent 80 which coatsdroplets 16 withagent 80 to forminsulation coating 30,Fig. 1 , ondroplets 16 while they are in flight towardsurface 20. This createsmaterial 32 havingdomains 34,Figs 5A-5B , withinsulated boundaries 36, e.g., as discussed above. -
Droplet spray subsystem 12,Figs. 1-4 ,6 and7 , may be a uniform droplet spray system configured to generatedroplets 16 having a uniform diameter. -
System 10,Figs. 1-4 ,6 and7 and the corresponding method thereof for makingmaterial 32 that includes domains with insulated boundaries may be an alternative material and manufacturing process for the motor cores, or any similar type device which may benefit from a material having domains with insulated boundaries as will be described in greater detail below. The stator winding cores of an electric motor may be fabricated using the system and method of one or more embodiments of this invention.System 10 may be a single-step net-shape fabrication process which preferably uses dropletspray deposition subsystem 12 and reactive atmosphere introduced byport 24 to facilitate controlled formation of insulation layers 30 on the surfaces ofdroplets 16, as discussed above with reference toFigs. 1-7 . - The material chosen to form
droplets 16 makesmaterial 32 highly permeable with low coercivity and high saturation induction.Boundaries 36,Figs. 5A-5B may somewhat deteriorate the capability ofmaterial 32 to provide good magnetic paths. However, becauseboundaries 36 may be very thin, e.g., about 0.05 µm to about 5.0 µm, and becausematerial 32 may be very dense, this deterioration is relatively small. This, in addition to the low cost of makingmaterial 32, is another advantage over conventional SMC, discussed in the Background Section above, which have larger gaps between individual grains as the mating surfaces of neighboring grains of metal powder in SMC do not match perfectly.Insulation boundaries 36 limit electrical conductivity between neighboringdomains 34.Material 32 provides a superior magnetic path due to its permeability, coercivity and saturation characteristics. The limited electrical conductivity ofmaterial 30 minimizes eddy current losses associated with rapid changes of the magnetic field as the motor rotates. - Hybrid-field geometries of electric motors may be developed using
material 32 withdomains 34 withinsulated boundaries 36.Material 32 may eliminate design constraints associated with anisotropic laminated cores of conventional motors. The system and method of makingmaterial 32 of one or more embodiments of this invention may allow for the motor cores to accommodate built-in cooling passages and cogging 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 makingmaterial 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. Patent 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. - In a conventional UDS process, metal in a crucible is melted by a heater and ejected through an orifice by pressure applied from an inert gas supply. The ejected molten metal forms a laminar jet, which is vibrated by a piezoelectric transducer at a specified frequency. The disturbance from the vibration causes a controlled breakup of the jet into a stream of uniform droplets. A charging plate may be utilized in some applications to electrically charge the droplets so that they repel each other, preventing merging.
-
System 10 and method of makingmaterial 32 may use the fundamental elements of the conventional UDS deposition processes to createdroplets 16,Figs. 1-4 ,6 and7 , which have a uniform diameter.Droplet spray subsystem 12,Fig. 1 , may use a conventional UDS process that is combined with simultaneous formation ofinsulation layer 30 on the surface of thedroplets 16 during their flight to producedense 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 agas 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. - Thus far,
system 10 and the methods thereof forms an insulation layer on in-flight droplets to form a material having domains with insulated boundaries. In another disclosed embodiment,system 310,Fig. 8 , and the method thereof forms the insulation layer on droplets which have been deposited on a surface or substrate to form a material having domains with insulated boundaries.System 310 includesdroplet spray subsystem 312 configured to create and ejectmolten alloy droplets 316 fromorifice 322 and directmolten alloy droplets 316 towardssurface 320. Here,droplet spray subsystem 312 ejects molten alloy droplets intospray chamber 318. In alternate aspects,spray chamber 318 may not be required as discussed in further detail below. -
Droplet spray subsystem 312 may includecrucible 314 which createsmolten alloy droplets 316 and directsmolten alloy droplets 316 towardssurface 320 insidespray chamber 318. Here,crucible 314 may includeheater 342 which formsmolten alloy 344 inchamber 346. The material used to makemolten alloy 344 may have a high permeability, low coercivity and high saturation induction. In one example,molten alloy 344 may be made from a magnetically soft iron alloy, such as iron-base alloy, iron-cobalt alloy, nickel-iron alloy, silicon iron alloy, ferritic stainless steel or similar type alloy.Chamber 346 receivesinert gas 347 viaport 345. Here,molten alloy 344 is ejected throughorifice 322 due to the pressure applied frominert gas 347 introduced viaport 345.Actuator 350 with vibration transmitter 351 vibrates a jet ofmolten alloy 344 at a specified frequency to break upmolten alloy 344 into stream ofdroplets 316 which are ejected throughorifice 322.Crucible 314 may also includetemperature sensor 348. Although as showncrucible 314 includes oneorifice 322, in other examples,crucible 314 may have any number oforifices 322 as needed to accommodate higher deposition rates ofdroplets 316 onsurface 320, e.g., up to 100 orifices or more.Molten alloy droplets 316 are ejected fromorifice 322 and directed toward asurface 320 to formsubstrate 512 thereon as will be discussed in greater detail below. -
Surface 320 is preferably moveable, e.g., usingstage 340, which may be an X-Y stage, a turn table, a stage that can additionally change the pitch and roll angle ofsurface 320, or any other suitable arrangement that can supportsubstrate 512 and/or movesubstrate 512 in a controlled manner as it is formed. In one example,system 310 may include a mold (not shown) that is placed onsurface 320 to whichsubstrate 512 fills the mold. -
System 310 also may include one or more spray nozzles, e.g.,spray nozzle 500 and/orspray nozzle 502, configured to direct agent atsubstrate 512 of depositeddroplets 316 and createspray 506 and/orspray 508 ofagent 504 that is directed onto or abovesurface 514 ofsubstrate 512. Here,spray nozzle 500 and/orspray nozzle 502 are coupled tospray chamber 318. Spray 506 and/orspray 508 may form the insulating layer on surface of depositeddroplets 316 before or afterdroplets 316 are deposited onsubstrate 512, either by directly forming the insulating layer ondroplets 316 or by facilitating, participating, and/or accelerating a chemical reaction that forms the insulating layer on the surface ofdroplets 316 deposited onsurface 320. - For example,
spray agent 504 may be used to facilitate, participate, and/or accelerate a chemical reaction that forms insulation layers on depositeddroplets 316 that formsubstrate 512 or that are subsequently deposited onsubstrate 512. For example,spray substrate 512,Fig. 9 , indicated at 511. In this example,spray droplets 316 thereon) to form insulatinglayer 530 on the surface of depositeddroplets 316 as shown. As subsequent layers ofdroplets 316 are deposited,spray insulation layers 330 on the subsequent deposited layers of droplets, e.g., as indicated at 513, 515.Material 332 is created havingdomains 334 withinsulated boundaries 336 there between. -
Fig. 10A shows one example ofmaterial 332 that includesdomains 334 withinsulated boundaries 336 there between created using one embodiment ofsystem 310 discussed above with reference to one or more ofFigs. 8 and9 .Insulated boundaries 336 are formed frominsulation layer 330,Fig. 9 , ondroplets 316. In one example,material 332,Fig 10A , includesboundaries 336 between neighboringdomains 334 which are virtually perfectly formed as shown. In other examples,material 332,Fig. 10B , may include boundaries 336' betweenneighboring domains 334 with discontinuities as shown.Material 332,Figs. 9, 10A and 10B , reduces eddy current losses, anddiscontinuities boundaries 336 between neighboringdomains 334 improve the mechanical properties ofmaterial 332. The result is thatmaterial 332 may preserve a high permeability, a low coercivity and a high saturation induction of the alloy.Boundaries 336 limit electrical conductivity between neighboringdomains 334.Material 332 provides a superior magnetic path due to its permeability, coercivity and saturation characteristics. The limited electrical conductivity ofmaterial 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. 11 shows one embodiment ofsystem 310,Fig. 8 , whereinspray Fig. 9 directly formsinsulation layers 330,Fig. 8 , on depositeddroplets 316 onsubstrate 512. In this example,substrate 512, is moved, e.g., in the direction indicated byarrow 517, usingstage 340,Fig. 8 .Spray Fig. 11 , is then directed at depositeddroplets 316 onsubstrate 512, indicated at 519.Insulation layer 330 then forms on each of the depositeddroplets 316 as shown. As subsequent layers ofdroplets 316 are deposited, indicated at 521, 523,spray agent 504 is sprayed thereon to directly createinsulation layer 330 on each of the deposited droplets of each new layer. The result ismaterial 332 is created which includesdomains 334 withinsulated boundaries 336, e.g., as discussed above with reference toFigs. 9-10B . -
Fig. 12 shows one example ofsystem 310,Fig. 8 , whereinspray Fig. 12 , is sprayed onsubstrate 512 to form an insulation layer thereon beforedroplets 316 are deposited, indicated at 525. Thereafter,spray droplets 316 onsubstrate 512 to forminsulation layer 330 indicated at 527, 529. The result ismaterial 332 is created which includesdomains 334 withinsulated boundaries 336, e.g., as discussed above with reference toFigs. 10A-10B . - Insulating
layer 330 on depositeddroplets 16 may be formed by a combination of any of the processes discussed above with reference to one or more ofFigs. 8-12 . The two processes may take place in sequence or simultaneously. - In one example,
agent 504 that createsspray 506 and/orspray 508,Figs. 8-12 , may be ferrite powder, a solution containing ferrite powder, an acid, water, humid air or any other suitable agent involved in the process of producing an insulating layer on the surface of the substrate. - System 310',
Fig. 13 , where like parts have like numbers, preferably includeschamber 318 with separation barrier 524 that createssub-chambers opening 529 configured to allowdroplets 316, e.g., droplets ofmolten alloy 344 or similar type material, to flow fromsub-chamber 526 tosub-chamber 528.Sub-chamber 526 may includegas inlet 528 andgas 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 includegas inlet 530 andgas exhaust 532 configured to maintain predetermined pressure and gas mixture insub-chamber 528, e.g., as substantially reactive gas mixture. - The predetermined pressure in
sub-chamber 526 may be higher than the predetermined pressure insub-chamber 528 to limit the flow of gas fromsub-chamber 526 tosub-chamber 528. In one example, the substantially neutral gas mixture insub-chamber 526 may be utilized to prevent reaction withdroplets 316 withorifice 322 on the surface ofdroplets 316 before they land on the surface ofsubstrate 512. The substantially reactive gas mixture insub-chamber 528 may be introduced to participate, facilitate and/or accelerate in a chemical reaction withsubstrate 512, and subsequent layers of depositeddroplets 316, to form an insulatinglayer 330 on depositeddroplets 316. For example, insulatinglayer 330,Fig. 14 , may be formed on depositeddroplets 316 after they land onsubstrate 512. The depositeddroplets 316 react with the reactive gas insub-chamber 528,Fig. 13 which facilitates, participates, and/or accelerates a chemical reaction to createinsulation layer 330 indicated at 531. As subsequent layers of droplets are added, the gas insub-chamber 528 may facilitate, participates, and/or accelerates a reaction withdroplets 316 to createinsulation layers 330 onsubstrate 512, indicated at 533 and 535.Material 332 havingdomains 334 withinsulated boundaries 336 there between is then formed, e.g., as discussed above with reference toFigs 10A-10B . -
System 310",Fig. 15 , where like parts have like numbers, preferably includeschamber 314 with only onechamber 528. In this design,droplets 316 are directed directly intochamber 528 which is preferably designed to minimize the travel distance ofdroplets 316 betweenorifice 322 andsurface 510 ofsubstrate 512. This preferably limits the exposure ofdroplets 316 to the substantially reactive gas mixture insub-chamber 528.System 310" createsmaterial 332 in a similar manner to system 310',Fig. 14 . - For the deposition process of
droplets 316,system 310,Figs. 8-9 and11-15 provides for movingsubstrate 512 onsurface 320 ofstage 340 with respect to the stream ofdroplets 316 ejected from thecrucible 314 or similar type device.System 310 may also provide for deflectingdroplets 316, for example, with magnetic, gas flow or other suitable deflection system. Such deflection may be used alone or in combination withstage 340. In either case,droplets 316 are deposited in a substantially discrete manner, i.e., twoconsecutive droplets 316 may exhibit limited or no overlap upon deposition. As an example, the following relationship may be satisfied for discrete deposition in accordance with one or more embodiment of system 310:droplets 316 fromcrucible 314, and ds is diameter of splat formed by a droplet after landing on the surface of the substrate. - Examples of the one of more aspects of the disclosed embodiment of
system 310 performing discrete deposition ofdroplets 316 are shown in one or more ofFigs. 8-9 and11-15 . In one embodiment, the relative motion ofsubstrate 512 with respect to the stream ofdroplets 316 may be controlled so that discrete deposition across an area of a substrate is achieved, e.g., as shown inFig. 16 . The following relationships may be used for this example of the deposition process of droplets 316:droplets 316 and m and n are offsets to each consecutive layer ofdroplets 316. - In the example shown in
Fig. 16 , the motion ofsubstrate 512 onstage 340,Figs. 8 ,13 and15 may be controlled so that rows A, B and C,Fig. 16 , are deposited consecutively in a discrete manner. For example, rows A1, B1, C1 may represent the first layer, indicated asLayer 1, rows A2, B2, C2 may represent the second layer, indicated asLayer 2, and rows A3, B3, C3 may represents the third layer, indicated byLayer 3 of the depositeddroplets 316. In the pattern shown inFig. 16 , the layer arrangement may repeat itself after the third layer, i.e., thelayer following Layer 3 will be identical in spacing and positioning asLayer 1. Alternatively, the layers may repeat after every second layer. Alternately, any suitable combination of layers or patterns may be provided. -
System 310,Figs. 8 ,13 and15 , may includenozzle 323 having plurality of spaced orifices, e.g., spacedorifices 322,Fig. 17 , employed to deposit multiple rows ofdroplets 316 simultaneously to achieve higher deposition rates. As shown inFigs. 16 and17 , the deposition process ofdroplets 316 discussed above may result inmaterial 332 having domains with insulated boundaries there between, discussed in detail above. - Although as discussed above with reference to
Figs. 8 ,13 and15 ,droplet spray subsystem 312 is shown havingcrucible 314 configured to ejectmolten alloy droplets 316 intospray chamber 318, this is not a necessary limitation of the disclosed embodiment.System 310,Fig. 18 , where like parts have been given like numbers, may include droplet spray subsystem 312'. In this example, droplet spray subsystem 312' preferably includes wire arcdroplet spray subsystem 550 which createsmolten alloy droplets 316 and directsmolten alloy droplets 316 towardssurface 320 insidespray chamber 318. Wire arcdroplet spray subsystem 550 also preferably includeschamber 552 which houses positivewire arc wire 554 andnegative arc wire 556.Alloy 558 may be disposed in each ofarc wires alloy 558 used to createdroplets 316 sprayed towardsubstrate 512 may be composed mainly of iron (e.g., greater than about 98%) with very low amount of carbon, sulfur, and nitrogen content, (e.g., less than about 0.005%) and may include minute quantities of Al and Cr (e.g., less than about 1%) with the balance, in this example, being Si to achieve good magnetic properties. The metallurgical composition may be tuned to provide improvements in the final properties of the material having domains with insulated boundaries.Nozzle 560 is shown configured to introduce one ormore gases gas 568 insidechamber 552 andchamber 318. Preferably,pressure control valve 566 controls the flow of one or more ofgases chamber 552. - In operation, the voltage applied to
positive arc wire 554 andnegative arc wire 556 createsarc 570 which causesalloy 558 to formmolten alloy droplets 316, which are directed towardssurface 320 insidechamber 318. In one example, voltages between about 18 and 48 volts and currents between about 15 to 400 amperes may be applied topositive arc wire 554 andnegative arc wire 556 to provide a continuous wire arc spray process ofdroplets 316. The depositedmolten droplets 316 may react on the surface with surroundinggas 568, also shown inFigs. 19-20 , to develop a non-conductive surface layer on depositeddroplets 316. This layer may serve to suppress eddy current losses inmaterial 332,Figs. 10A-10B , having domains with insulated boundaries. For example, surroundinggas 568 may be atmospheric air. In this case, oxide layers may form oniron droplets 316. These oxide layers may include several chemical species, including, e.g., FeO, FezOs, 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 ofFigs. 8-9 and11-15 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, includesdroplet spray subsystem 312".Subsystem 312" includes wire arc deposition subsystem 550' that createsmolten alloy droplets 316 and directsmolten alloy droplets 316 towardssurface 320. In this example,droplet spray subsystem 312" does not includechamber 552,Fig. 18 , andchamber 318. Instead,nozzle 560,Fig. 19 , is configured to introduce one ormore gases gas 568 in the area proximatepositive arc wire 554 andnegative arc wire 556.Gas 568 propelsdroplets 316 towardsurface 514. Spray 506 and/orspray 508 ofagent 504 is then directed onto or abovesurface 514 ofsubstrate 512, having depositeddroplets 316 thereon, e.g., usingspray nozzle 513, similar as discussed above. In this design, a shroud, e.g.,shroud 523, may besurround spray 506 and/orspray 508 ofagent 504 anddroplets 316 which are deposited onsubstrate 512. -
System 310‴,Fig. 20 , where like parts have been given like numbers, is similar tosystem 310",Fig. 19 , except wirearc spray subsystem 550" includes a plurality ofpositive arc wire 554,negative arc wires 556 andnozzles 560 which may be used simultaneously to achieve higher spray deposition rates ofmolten 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/orspray 508 ofagent 504 is directed onto or abovesurface 514 ofsubstrate 512, similar as discussed above with reference toFig. 19 . Here, a shroud, e.g.,shroud 523, may surroundspray 506 and/orspray 508 ofagent 504 anddroplets 316 deposited onsubstrate 512. - In other examples,
droplet spray subsystem 312 shown in one or more ofFigs. 8-19 may include one or more of a plasma spray droplet deposition subsystem, a detonation spray droplet depositions subsystem, a flame spray droplet deposition subsystem, a high velocity oxygen fuel spray (HVOF) droplet deposition subsystem, a warm spray droplet deposition subsystem, a cold spray droplet deposition subsystem, and a wire arc droplet deposition subsystem, each configured to form the metal alloy droplets and direct the molten alloy droplets towardssurface 320. - Wire arc spray
droplet deposition subsystem 550,Figs. 19-20 , may form the insulating boundaries by controlling and facilitating one or more of the following spray parameters: wire speed, gas pressure, shroud gas pressure, spraying distance, voltage, current, speed of substrate motion, and/or the speed of arc tool movement. One or more of the following process choices may also be optimized to attain improved structure and properties of the material having domains with insulated boundaries: composition of wires, composition of shroud gas/atmosphere, preheating or cooling of atmosphere and/or substrate, in process cooling and/or heating of substrate and/or part. A composition of two or more gases may be employed in addition to pressure control to improve process outcomes. -
Droplet spray subsystem 312,Figs. 8 ,13 ,15 ,18 ,19, and 20 may be mounted on a single or plurality of robotic arms and/or mechanical arrangements so as to improve part quality, reduce spray time, and improve process economics. The subsystems may spraydroplets 316 simultaneously at the same approximate location or may be staggered so as the spray a certain location in a sequential manner.Droplet spray subsystem 312 may be controlled and facilitated by controlling one or more of the following spray parameters: wire speed, gas pressure, shroud gas pressure, spraying distance, voltage, current, speed of substrate motion, and/or the speed of arc tool movement. - In any aspect of the disclosed embodiments discussed above, the overall magnetic and electric properties of the formed material having domains with insulated boundaries may be improved by regulating the properties of the insulating material. The permeability and resistance of the insulating material has a significant impact on the net properties. The properties of the net material having domains with insulated boundaries may thus be improved by adding agents or inducing reactions which improve the properties of the insulation, e.g., the promotion of Mn, Zn spinel formation in iron oxide based insulation coating may significantly improve the overall permeability of the material.
- Thus far,
system 10 andsystem 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 includescombustion chamber 612 andgas inlet 614 which injectsgas 616 intochamber 612.Fuel inlet 618 injectsfuel 620 intochamber 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 insidechamber 612.Igniter 622 is configured to ignite the flammable mixture of fuel and gas to create a predetermined temperature and pressure incombustion chamber 612.Igniter 622 may be a spark plug or similar type device. The resulting combustion increases the temperature and pressure withincombustion chamber 612 and the combustion products are propelled out ofchamber 612 viaoutlet 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 intocombustion chamber 612 viainlet 626.Metal powder 624 is preferably comprised ofmetal particles 626 coated with an insulating material. As shown bycaption 630,particles 626 ofmetal powder 624 includeinner core 632 made of a soft magnetic material, such as iron or similar type material, andouter layer 634 made of the electrically insulating material preferably comprised of ceramic-based materials, such as alumina, magnesia, zirconia, and the like, which results inouter layer 634 having a high melting temperature. In one example,metal powder 624 comprised ofmetal particles 626 havinginner core 632 coated with insulatingmaterial 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. - After
metal powder 624 is injected into pre-conditionedcombustion chamber 612,particles 626 ofmetal powder 624 undergo softening and partial melting due to the high temperature inchamber 612 to form conditioneddroplets 638 insidechamber 612. Preferably, conditioneddroplets 638 have a soft and/or partially meltedinner core 632 made of a soft magnetic material and a solidouter layer 634 made of the electrically insulated material. Conditioneddroplets 638 are then accelerated and ejected fromoutlet 624 asstream 640 that includes both combustion gases and conditioneddroplets 638. As shown incaption 642,droplets 638 instream 640 preferably have a completely solidouter layer 634 and a softened and/or partially meltedinner core 632.Stream 640, carrying conditioneddroplets 638, is directed atstage 644.Stream 640 is preferably traveling in a predetermined speed, e.g., about 350m/s. Conditioneddroplets 638 then impactstage 644 and adhere thereto to form material 648 having domains with insulated boundaries thereon.Caption 650 shows in further detail one example ofmaterial 648 withdomains 650 of soft magnetic material with electrically insulatedboundaries 652. -
Fig. 22A shows an example ofmaterial 48 that includesdomains 650 withinsulated boundaries 652 therebetween. In one example,material 648 includesboundaries 652 between neighboringdomains 650 which are virtually perfectly formed as shown. In other examples,material 648,Fig. 22B , may include boundaries 652' betweenneighboring domains 50 with discontinuities as shown.Material 648,Figs. 22A and 22B , reduces eddy current losses anddiscontinuities boundaries 652 between neighboringdomains 650 improve the mechanical properties ofmaterial 648. The result is thatmaterial 648 preserves a high permeability, a low coercivity and a high saturation induction of the alloy.Boundaries 652 limit electrical conductivity between neighboringdomains 650.Material 648 preferably provides a superior magnetic path due to its permeability, coercivity and saturation characteristics. The limited electrical conductivity ofmaterial 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. -
System Figs. 1-22B , provides for formingbulk material metal material source System support Support System deposition device coating device deposition path metal material boundaries domains boundaries magnetic bulk material magnetic material source support Heating device deposition device device deposits particles domains boundaries - Referring now to
Figs. 23A and 23B , there is shown one example of a cross section ofbulk material 700.Bulk material 700 may be a soft magnetic material and may have features as discussed above, for example, with respect tomaterial Figs. 23A and 23B also show cross sections of spray deposited bulk material, for example, a cross section of the multi layered material as shown, e.g., inFig. 16 . Here,bulk material 700,Figs. 23A and 23B , is shown formed onsurface 702.Bulk material 700 has a plurality of adhereddomains 710 of metal material, substantially all of the domains of the plurality of domains of metal material separated by a predetermined layer of highresistivity insulating material 712. The metal material may be any suitable metal material. Afirst portion 714 of the plurality of domains of metal material is shown forming a formedsurface 716 corresponding to thesurface 702. Asecond portion 718 of the plurality ofdomains 710 of metal material is shown having successive domains, e.g.,domains first portion 714. Substantially all of the domains in thesuccessive domains arrow 733 betweenfirst surface 730 andsecond surface 732. A majority of the domains in the successive domains of metal material have the first surface being a substantially convex surface and the second surface having one or more substantially concave surfaces. The layer of high resistivity insulating material may be any suitable electrically insulating material. For example, in one aspect the layer may be selected from materials having a resistivity greater than about 1×103Ω-m. In another aspect, the electrically insulating layer or coating may have high electrical resistivity, such as with materials alumina, zirconia, boron nitride, magnesium oxide, magnesia, titania or other suitable high electrical resistivity material. In another aspect, the layer may be selected from materials having a resistivity greater than about 1×108 Ω-m. The layer of high resistivity insulating material may have a selectable thickness that is substantially uniform, for example, as disclosed. The metal material may also be a ferromagnetic material. In one aspect, the layer of high resistivity insulating material may be ceramic. Here, the first surface and the second surface may form an entire surface of the domain. The first surfaces may progress in a substantially uniform direction from the first portion.Bulk material 700 may be a soft magnetic bulk material formed onsurface 702 where the soft magnetic bulk material has a plurality ofdomains 710 of magnetic material, each of the domains of the plurality of domains of magnetic material substantially separated by a selectable coating of highresistivity insulating material 712. Afirst portion 714 of the plurality of domains of magnetic material may form a formedsurface 716 corresponding to surface 702 while asecond portion 718 of the plurality of domains of magnetic material hassuccessive domains first portion 714. Substantially all of the domains in the successive domains of magnetic material have first 730 and second 732 surfaces with the first surface having a substantially convex surface and the second surface having one or more substantially concave surfaces. In another aspect, voids 740 may exist inmaterial 700 shown inFig. 23B . Here, the magnetic material may be a ferromagnetic material and the selectable coating of high resistivity insulating material may be ceramic with the first surface substantially opposing the second surface and with the first surfaces progressing in a substantiallyuniform direction 741 from thefirst portion 714. - As will be described with respect to
Figs. 24-36 , electrical devices are shown that may be coupled to an electrical power source. In each case, the electrical device has a soft magnetic core with material as disclosed herein and a winding coupled to the soft magnetic core and surrounding a portion of the soft magnetic core with the winding coupled to the power source. In alternate aspects, any suitable electrical device that has a core or soft magnetic core with material as disclosed herein may be provided. For example and as disclosed, the core may have a plurality of domains of magnetic material, each of the domains of the plurality of domains of magnetic material substantially separated by a layer of high resistivity insulating material. The plurality of domains of magnetic material may have successive domains of magnetic material progressing through the soft magnetic core with substantially all of the successive domains of magnetic material having first and second surfaces, the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces. Here and as disclosed, the second surface conforms to the shape of the domains of metal material that the second surface has progressed from with a majority of the domains in the successive domains of metal material having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces. By way of example, the electrical device may be an electric motor coupled to a power source, the electric motor having a frame with a rotor and a stator coupled to the frame. Here, either the rotor or the stator may have a winding coupled to the power source and a soft magnetic core with the winding wound about a portion of the soft magnetic core. The soft magnetic core may have a plurality of domains of magnetic material, each of the domains of the plurality of domains of magnetic material substantially separated by a layer of high resistivity insulating material as disclosed herein. In alternate aspects, any suitable electrical device that has a soft magnetic core with material as disclosed herein may be provided. - Referring now to
Fig. 24 , there is shown an exploded isometric view ofbrushless motor 800.Motor 800 is shown havingrotor 802, stator 804 andhousing 806.Housing 806 may have position sensor orhall elements 808. Stator 804 may havewindings 810 andstator core 812.Rotor 802 may haverotor core 814 andmagnets 816. In the disclosed embodiment,stator core 812 and/orrotor core 814 may be fabricated from the material and methods discussed above having insulated domains and the methods thereof disclosed above. Here,stator core 812 and/orrotor core 814 may be fabricated either completely or in part from bulk material such asmaterial motor 800 may be made from such material and wheremotor 800 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 25 , there is shown a schematic view ofbrushless motor 820.Motor 820 is shown havingrotor 822,stator 824 andbase 826.Motor 820 may also be an induction motor, a stepper motor or similar type motor.Housing 827 may have position sensor orhall elements 828.Stator 824 may havewindings 830 andstator core 832.Rotor 822 may haverotor core 834 andmagnets 836. In the disclosed embodiment,stator core 832 and/orrotor core 834 may be fabricated from the disclosed materials and/or by the methods discussed above. Here,stator core 832 and/orrotor core 834 may be fabricated either completely or in part from bulk material such asmaterial motor 820 may be made from such material and wheremotor 820 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 26A , there is shown a schematic view oflinear motor 850.Linear motor 850 has primary 852 and secondary 854. Primary 852 hasprimary core 862 andwindings secondary plate 864 andpermanent magnets 866. In the disclosed embodiment,primary core 862 and/orsecondary plate 864 may be fabricated from the materials and/or by the disclosed methods disclosed herein. Here,primary core 862 and/orsecondary plate 864 may be fabricated either completely or in part from bulk material, such asmaterial motor 850 may be made from such material and wheremotor 850 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 26B , there is shown a schematic view oflinear motor 870.Linear motor 870 has primary 872 and secondary 874. Primary 872 hasprimary core 882,permanent magnets 886 andwindings secondary plate 884. In the disclosed embodiment,primary core 882 and/orsecondary plate 884 may be fabricated from the materials and/or by the disclosed methods disclosed herein. Here,primary core 882 and/orsecondary plate 884 may be fabricated either completely or in part from bulk material such asmaterial motor 870 may be made from such material and wheremotor 870 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 27 , there is shown an exploded isometric view of electric generator 890. Generator or alternator 890 is shown havingrotor 892,stator 894 and frame or housing 896. Housing 896 may have brushes 898.Stator 894 may havewindings 900 andstator core 902.Rotor 892 may haverotor core 895 andwindings 906. In the disclosed embodiment,stator core 902 and/orrotor core 895 may be fabricated from the disclosed materials and / or by the disclosed methods. Here,stator core 902 and/or rotor core 904 may be fabricated either completely or in part from bulk material, such asmaterial - Referring now to
Fig. 28 , there is shown a cutaway isometric view of stepping motor 910. Motor 910 is shown havingrotor 912,stator 914 andhousing 916.Housing 916 may havebearings 918.Stator 914 may havewindings 920 andstator core 922.Rotor 912 may haverotor cups 924 andpermanent magnet 926. In the disclosed embodiment,stator core 922 and/orrotor cups 924 may be fabricated from the disclosed materials and/or by the disclosed methods. Here,stator core 922 and/orrotor cups 924 may be fabricated either completely or in part from bulk material such asmaterial - Referring now to
Fig. 29 , there is shown an exploded isometric view of anAC motor 930.Motor 930 is shown havingrotor 932,stator 934 andhousing 936.Housing 936 may havebearings 938.Stator 934 may havewindings 940 and stator core 942.Rotor 932 may haverotor core 944 andwindings 946. In the disclosed embodiment, stator core 942 and/orrotor core 944 may be fabricated from the disclosed materials and/or by the disclosed methods. Here, stator core 942 and/orrotor core 944 may be fabricated either completely or in part from bulk material such asmaterial motor 930 may be made from such material and wheremotor 930 may be any suitable electric motor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 30 , there is shown a cutaway isometric view of anacoustic speaker 950.Speaker 950 is shown havingframe 952,cone 954,magnet 956, winding orvoice coil 958 andcore 960. Here,core 960 may be fabricated either completely or in part from bulk material such asmaterial speaker 950 may be made from such material and wherespeaker 950 may be any suitable speaker or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 31 , there is shown a isometric view oftransformer 970.Transformer 970 is shown havingcore 972 and coil orwindings 974. Here,core 972 may be fabricated either completely or in part from bulk material such asmaterial transformer 970 may be made from such material and wheretransformer 970 may be any suitable transformer or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Figs. 32 and 33 , there is shown a cutaway isometric view ofpower transformer 980.Transformer 980 is shown having oil filledhousing 982,radiator 984,core 986 and coil orwindings 988. Here,core 986 may be fabricated either completely or in part from bulk material such asmaterial transformer 980 may be made from such material and wheretransformer 980 may be any suitable transformer or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 34 , there is shown a schematic view ofsolenoid 1000.Solenoid 1000 is shown havingplunger 1002, coil or winding 1004 andcore 1006. Here,core 1006 and/orplunger 1002 may be fabricated either completely or in part from bulk material such asmaterial solenoid 1000 may be made from such material and wheresolenoid 1000 may be any suitable solenoid or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 35 , there is shown a schematic view of aninductor 1020.Inductor 1020 is shown having coil or winding 1024 andcore 1026. Here,core 1026 may be fabricated either completely or in part from bulk material such asmaterial inductor 1020 may be made from such material and whereinductor 1020 may be any suitable inductor or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. -
Fig. 36 is a schematic view of a relay orcontactor 1030.Relay 1030 is shown havingcore 1032, coil or winding 1034,spring 1036,armature 1038 andcontacts 1040. Here,core 1032 and/orarmature 1038 may be fabricated either completely or in part from bulk material such asmaterial relay 1030 may be made from such material and whererelay 1030 may be any suitable relay or device using as any component or a portion of a component fabricated from the highly permeable magnetic material having domains of highly permeable magnetic material with insulated boundaries. - Referring now to
Fig. 37 , there is shown another aspect of the disclosed embodiment with respect tosystem 1100.System 1100 may be provided for forming a soft magnetic bulk material of a predetermined shape from amagnetic 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 todeposition 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 ofmagnetic material 1112 where the material is in powder form, solid form or otherwise and where the material is deposited bydeposition 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 withinenclosure 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 fromdeposition source 1114 as disclosed. By way of example, the reactive gas may be oxygen or air where an oxide is grown on the surface ofparticles 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 hasheating device 1120,deposition device 1114 andsupport 1122 configured to support the soft magnetic bulk material of thepredetermined shape 1110.Masks predetermined shape 1110. Theheating device 1120 heats the magnetic material to form particles having a softenedstate 1118 and wherein thedeposition device 1114 depositssuccessive layers 1128...1130 of particles of the magnetic material in the softenedstate 1118 on thesupport 1122 with themasks deposition device 1114 and thesupport 1122. Here, the mask subsystem is indexed in the direction ofarrow 1132 to aposition 1134 relative to thesupport 1122 upon deposition of thesuccessive 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 thesupport 1122 forming the soft magnetic bulk material of apredetermined shape 1110 on thesupport 1122. First 1124 andsecond masks 1126 are shown coupled to each other such that when they are indexed, they block deposition of the magnetic material onportions 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 depositedmetal 1118 may in one aspect not stick to mask 1124, 1126.Support 1122 andmask plane 1146 such that material may be selectively deposited on any portion ofmaterial 1110. Further one or more portions of the mask may be moveable relative to the other. For example, when the masks are indexed, eithermask 1126 ormask 1124 may be moveable relative to the other. Referring also tofigures 38 ,29 and40 , by way of example, the soft magnetic bulk material of apredetermined shape 1110 on thesupport 1122 may be astator 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 Fig's. 39 and 40 respectively. If the stator is to have skewed teeth, theinner mask 1126 may be rotated 1150 slightly with each successive index where thefirst mask 1126 is moveable relative to thesecond 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 m1124, 1126 ay be more than one mask having different shapes corresponding to different cross sections of the soft magnetic bulk material of apredetermined 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 abulk material 1200. Here, the bulk material may be in powdered or particulate form.Bulk material 1200 hasiron particles 1210 with the iron particles having athin layer 1212 of iron oxide on the surface of theiron particles 1210. Between the iron oxide coated iron particles are also particles ofaluminum 1214. The iron oxide may occur naturally from exposure or purposefully, for example, by acid bath or otherwise. Referring also toFig. 42 ,heat 1220 is 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 is started whereby the following reaction may take place with respect to the iron oxide coating and the aluminum
Fe2O3 + 2AI => Al2O3 + 2Fe
- The reaction results in a structure 1200' as seen in
Fig. 42 wherebyiron particles 1210 reside in a composite structure and surrounded byaluminum oxide 1222 forming a soft magneticmaterial having domains 1210 of magnetic material surrounded by insulatingmaterial 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. According to the invention, a method of forming a soft magnetic bulk material of a predetermined shape from amagnetic material 1210 and anon-magnetic material 1214 wherein the magnetic material comprises coated iron particles, is provided by providing a reservoir adapted to contain the soft magnetic bulk material of the predetermined shape as will be described. Here, aheat source 1220 is provided for heating the magnetic material and the non-magnetic material in the reservoir to an ignition temperature of a thermite reaction thus forming the soft magnetic bulk material of a predetermined shape. Here, the soft magnetic bulk material hasdomains 1210 formed from the magnetic material with insulatingboundaries 1222 formed from the reaction. -
Fig. 43 shows an example of anapparatus 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 haspowder delivery piston 1260,powder delivery reservoir 1262, roller orpusher 1264,fabrication piston 1270, object being fabricated 1268,fabrication powder bed 1266, heat source andalternate powder source 1276.Scanning platform 1280 selectively positionsheat source 1274 andpowder source 1276 to direct heat and material to a portion offabrication powder bed 1266 to turn the bulk material from powder form to solid form. In practice, iron particles with iron oxide coating are provided withinreservoir 1262. In the embodiment shown, support orpiston 1270 may be heated, for example, to facilitate the reaction or stress relievepart 1268. To build successive layers ofobject 1268,fabrication piston 1270 is indexed down an increment andpowder delivery piston 1260 is indexed up an increment. Roller orpusher 1264 pushes a layer of material frompowder reservoir 1262 to replenish thefabrication powder bed 1266 with a fresh layer of powder.Scanner 1280 selectively movesheat source 1274 andalternate 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, thepowder 1262 may be iron oxide coated iron particles, theheat source 1274 may be a switchable laser and thealternative powder source 1276 may be a switchable, viametering valve 1282, pressurized stream ofaluminum powder 1286. In practice,Scanner 1280 selectively moveslaser 1274 andaluminum source 1276 to solidify a portion of thefresh bed 1266 of iron powder to build up the next layer of the object being fabricated 1268. Here, thelaser 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 ofbed 1266 corresponding to the fabricatedpart 1268. Here, a method of forming a soft magnetic bulk material of apredetermined shape 1268 from amagnetic material 1262 and anon-magnetic material 1286 is provided by providing areservoir predetermined shape 1268; providing aheat source 1274 and heating themagnetic material 1262 and thenon-magnetic material 1286 in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of apredetermined shape 1268. Here, the softmagnetic bulk material 1268 has domains formed from the magnetic material with insulating boundaries formed from the reaction as described with respect toFigs. 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 hasmoveable support 1310,heat source 1312 andpowder source 1314 andalternate powder source 1316.Scanning platform 1318 selectively positionsheat source 1314 andpowder sources 1316 to direct heat and material to a portion ofsupport 1310 to turn the powder material fromsources reservoir powder source 1314 and aluminum powder is provided withinpowder source 1316. In the embodiment shown,support 1310 may be heated, for example, to facilitate the reaction or stress relievepart 1318. To build successive layers ofobject 1318,indexer 1320 is indexed down an increment to lowersupport 1310Scanner 1318 selectively movesheat source 1312,powder source 1314 andalternate 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 tosupport 1310. In the embodiment shown, the switchable, viametering valve 1326,pressurized powder stream 1322 may be iron oxide coated iron particles, theheat source 1312 may be a switchable laser and thealternative powder source 1316 may be a switchable, viametering valve 1328, pressurized stream ofaluminum powder 1324. In practice,Scanner 1280 selectively moveslaser 1312,iron powder source 1314 andaluminum powder source 1316 to deposit and solidify a portion of the object being fabricated 1319. Here, thelaser 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 fabricatedpart 1318. In alternate aspects, laser may not be provided, for example, where thepowder 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 insource 1314. 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 Fig's. 23 A& B or otherwise as disclosed. Here, a method of forming a soft magnetic bulk material of apredetermined shape 1318 from amagnetic material 1322 and anon-magnetic material 1324 is provided by providing areservoir 1310 adapted to contain the soft magnetic bulk material of thepredetermined shape 1318; providing aheat source 1312 and heating themagnetic material 1322 and thenon-magnetic material 1324 in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of apredetermined shape 1310. Here, the softmagnetic bulk material 1318 has domains formed from the magnetic material with insulating boundaries formed from the reaction as described with respect to Fig's 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 andheat source 1356. The heat source triggers a thermite reaction as described turning thepowder mixture 1354 into asolid part 1358 as the reaction travels through the part. Here, a method of forming a soft magnetic bulk material of apredetermined shape 1358 from a magnetic material and anon-magnetic material 1354 is provided by providing areservoir 1352 adapted to contain the soft magnetic bulk material of thepredetermined shape 1358; providing aheat source 1356 and heating the magnetic material and thenon-magnetic material 1354 in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of apredetermined shape 1358. Here, the softmagnetic bulk material 1358 has domains formed from the magnetic material with insulating boundaries formed from the reaction as described with respect to Fig's 41 and 42. - Although specific features of the disclosed embodiment are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. The words "including", "comprising", "having", and "with" as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection.
Claims (7)
- A method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a non-magnetic material, wherein the magnetic material comprises coated iron particles, the method comprising:
providing a reservoir adapted to contain the soft magnetic bulk material of the predetermined shape;providing a heat source; andheating the magnetic material and the non-magnetic material in the reservoir to an ignition temperature of a thermite reaction thus forming the soft magnetic bulk material of a predetermined shapewherein the soft magnetic bulk material of a predetermined shape has domains formed from the magnetic material with insulating boundaries formed from the reaction. - The method of claim 1, wherein the reservoir comprises a movable support.
- The method of claim 1, wherein the heat source comprises a laser.
- The method of claim 1, wherein the domains comprise iron and wherein the insulating material comprises aluminum oxide.
- The method of claim 1, wherein the non magnetic material comprises aluminum.
- The method of claim 1, wherein forming the soft magnetic bulk material of a predetermined shape comprises an additive process.
- The method of claim 1, wherein the reservoir comprises a mold.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP23200660.1A EP4279630A3 (en) | 2013-03-15 | 2014-03-05 | Method for making a structured magnetic material with integrated particle insulation |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/836,615 US10022789B2 (en) | 2011-06-30 | 2013-03-15 | System and method for making a structured magnetic material with integrated particle insulation |
PCT/US2014/020736 WO2014149761A2 (en) | 2013-03-15 | 2014-03-05 | System and method for making a structured magnetic material with integrated particle insulation |
EP14769666.0A EP2969315B1 (en) | 2013-03-15 | 2014-03-05 | System and method for making a structured magnetic material with integrated particle insulation |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP14769666.0A Division EP2969315B1 (en) | 2013-03-15 | 2014-03-05 | System and method for making a structured magnetic material with integrated particle insulation |
EP14769666.0A Division-Into EP2969315B1 (en) | 2013-03-15 | 2014-03-05 | System and method for making a structured magnetic material with integrated particle insulation |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP23200660.1A Division EP4279630A3 (en) | 2013-03-15 | 2014-03-05 | Method for making a structured magnetic material with integrated particle insulation |
EP23200660.1A Division-Into EP4279630A3 (en) | 2013-03-15 | 2014-03-05 | Method for making a structured magnetic material with integrated particle insulation |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3792944A1 EP3792944A1 (en) | 2021-03-17 |
EP3792944B1 true EP3792944B1 (en) | 2023-11-08 |
Family
ID=51581602
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP20203613.3A Active EP3792944B1 (en) | 2013-03-15 | 2014-03-05 | Method for making a structured magnetic material with integrated particle insulation |
EP23200660.1A Pending EP4279630A3 (en) | 2013-03-15 | 2014-03-05 | Method for making a structured magnetic material with integrated particle insulation |
EP14769666.0A Active EP2969315B1 (en) | 2013-03-15 | 2014-03-05 | System and method for making a structured magnetic material with integrated particle insulation |
Family Applications After (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP23200660.1A Pending EP4279630A3 (en) | 2013-03-15 | 2014-03-05 | Method for making a structured magnetic material with integrated particle insulation |
EP14769666.0A Active EP2969315B1 (en) | 2013-03-15 | 2014-03-05 | System and method for making a structured magnetic material with integrated particle insulation |
Country Status (3)
Country | Link |
---|---|
EP (3) | EP3792944B1 (en) |
JP (1) | JP6173554B2 (en) |
WO (1) | WO2014149761A2 (en) |
Families Citing this family (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR102362218B1 (en) * | 2013-09-30 | 2022-02-11 | 퍼시몬 테크놀로지스 코포레이션 | Structures and methods utilizing structured magnetic material |
JP2017025386A (en) * | 2015-07-24 | 2017-02-02 | セイコーエプソン株式会社 | Three-dimensional molded object and three-dimensional molding method |
JP6661920B2 (en) * | 2015-08-26 | 2020-03-11 | セイコーエプソン株式会社 | 3D forming equipment |
TWI576872B (en) | 2015-12-17 | 2017-04-01 | 財團法人工業技術研究院 | Fabrication method of magnetic device |
US10622848B2 (en) * | 2016-04-11 | 2020-04-14 | Persimmon Technologies, Corp. | Material with directional microstructure |
TWI611851B (en) * | 2016-10-27 | 2018-01-21 | Printing device for molding liquid metal | |
US10720809B2 (en) | 2017-11-20 | 2020-07-21 | Hamilton Sundstrand Corporation | Rotor wedges with eddy current inhibitors |
IT201800002053A1 (en) * | 2018-01-26 | 2019-07-26 | Graf S P A | HEAD FOR THE THREE-DIMENSIONAL PRINTING OF MOLTEN METAL |
CN108597846B (en) * | 2018-06-06 | 2020-03-31 | 京磁材料科技股份有限公司 | Target type jet mill and method for preparing economical sintered neodymium iron boron blank |
US20210142933A1 (en) * | 2019-11-11 | 2021-05-13 | Carpenter Technology Corporation | Soft magnetic composite materials and methods and powders for producing the same |
US11904388B2 (en) | 2021-01-04 | 2024-02-20 | Additive Technologies Llc | Metal drop ejecting three-dimensional (3D) object printer having an increased material deposition rate |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4492180A (en) * | 1981-03-16 | 1985-01-08 | Applied Magnetics Corporation | Apparatus for indexing and registering a selected deposition mask to a substrate and method therefor |
US5266098A (en) | 1992-01-07 | 1993-11-30 | Massachusetts Institute Of Technology | Production of charged uniformly sized metal droplets |
US6919543B2 (en) * | 2000-11-29 | 2005-07-19 | Thermoceramix, Llc | Resistive heaters and uses thereof |
JP4683178B2 (en) * | 2001-03-12 | 2011-05-11 | 株式会社安川電機 | Soft magnetic material and manufacturing method thereof |
EP2727217B1 (en) * | 2011-06-30 | 2022-12-21 | Persimmon Technologies Corporation | Structured magnetic material |
US20150004312A1 (en) * | 2011-08-09 | 2015-01-01 | Applied Materials, Inc. | Adjustable mask |
-
2014
- 2014-03-05 EP EP20203613.3A patent/EP3792944B1/en active Active
- 2014-03-05 EP EP23200660.1A patent/EP4279630A3/en active Pending
- 2014-03-05 EP EP14769666.0A patent/EP2969315B1/en active Active
- 2014-03-05 JP JP2016500661A patent/JP6173554B2/en active Active
- 2014-03-05 WO PCT/US2014/020736 patent/WO2014149761A2/en active Application Filing
Also Published As
Publication number | Publication date |
---|---|
EP4279630A2 (en) | 2023-11-22 |
EP4279630A3 (en) | 2024-03-13 |
EP2969315A2 (en) | 2016-01-20 |
JP6173554B2 (en) | 2017-08-02 |
EP3792944A1 (en) | 2021-03-17 |
JP2016516896A (en) | 2016-06-09 |
WO2014149761A3 (en) | 2014-12-31 |
EP2969315A4 (en) | 2017-04-19 |
WO2014149761A2 (en) | 2014-09-25 |
EP2969315B1 (en) | 2020-12-02 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11623273B2 (en) | System and method for making a structured material | |
US10022789B2 (en) | System and method for making a structured magnetic material with integrated particle insulation | |
EP3792944B1 (en) | Method for making a structured magnetic material with integrated particle insulation |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE APPLICATION HAS BEEN PUBLISHED |
|
AC | Divisional application: reference to earlier application |
Ref document number: 2969315 Country of ref document: EP Kind code of ref document: P |
|
AK | Designated contracting states |
Kind code of ref document: A1 Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR |
|
RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: HOSEK, MARTIN Inventor name: SAH, SRIPATI |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: REQUEST FOR EXAMINATION WAS MADE |
|
17P | Request for examination filed |
Effective date: 20210915 |
|
RBV | Designated contracting states (corrected) |
Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR |
|
GRAP | Despatch of communication of intention to grant a patent |
Free format text: ORIGINAL CODE: EPIDOSNIGR1 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: GRANT OF PATENT IS INTENDED |
|
RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: SAH, SRIPATI Inventor name: HOSEK, MARTIN |
|
INTG | Intention to grant announced |
Effective date: 20230602 |
|
GRAS | Grant fee paid |
Free format text: ORIGINAL CODE: EPIDOSNIGR3 |
|
GRAA | (expected) grant |
Free format text: ORIGINAL CODE: 0009210 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE PATENT HAS BEEN GRANTED |
|
AC | Divisional application: reference to earlier application |
Ref document number: 2969315 Country of ref document: EP Kind code of ref document: P |
|
AK | Designated contracting states |
Kind code of ref document: B1 Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR |
|
P01 | Opt-out of the competence of the unified patent court (upc) registered |
Effective date: 20230929 |
|
REG | Reference to a national code |
Ref country code: GB Ref legal event code: FG4D |
|
REG | Reference to a national code |
Ref country code: CH Ref legal event code: EP |
|
REG | Reference to a national code |
Ref country code: DE Ref legal event code: R096 Ref document number: 602014088853 Country of ref document: DE |
|
REG | Reference to a national code |
Ref country code: IE Ref legal event code: FG4D |
|
RAP4 | Party data changed (patent owner data changed or rights of a patent transferred) |
Owner name: PERSIMMON TECHNOLOGIES, CORPORATION. |
|
RAP4 | Party data changed (patent owner data changed or rights of a patent transferred) |
Owner name: PERSIMMON TECHNOLOGIES CORPORATION |
|
REG | Reference to a national code |
Ref country code: NL Ref legal event code: FP |
|
REG | Reference to a national code |
Ref country code: LT Ref legal event code: MG9D |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: GR Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20240209 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: IS Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20240308 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: LT Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 |
|
REG | Reference to a national code |
Ref country code: AT Ref legal event code: MK05 Ref document number: 1630427 Country of ref document: AT Kind code of ref document: T Effective date: 20231108 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: NL Payment date: 20240326 Year of fee payment: 11 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: AT Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: ES Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: LT Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: IS Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20240308 Ref country code: GR Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20240209 Ref country code: ES Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: BG Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20240208 Ref country code: AT Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: PT Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20240308 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: DE Payment date: 20240327 Year of fee payment: 11 Ref country code: GB Payment date: 20240327 Year of fee payment: 11 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: SE Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: RS Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: PL Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: NO Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20240208 Ref country code: LV Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: HR Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: IT Payment date: 20240321 Year of fee payment: 11 Ref country code: FR Payment date: 20240325 Year of fee payment: 11 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: DK Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: CZ Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: SK Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: SM Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: SK Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: RO Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: EE Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: DK Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 Ref country code: CZ Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20231108 |