WO2000048772A2 - Appareil et procede de fabrication d'un composant electrique - Google Patents

Appareil et procede de fabrication d'un composant electrique Download PDF

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Publication number
WO2000048772A2
WO2000048772A2 PCT/US2000/003776 US0003776W WO0048772A2 WO 2000048772 A2 WO2000048772 A2 WO 2000048772A2 US 0003776 W US0003776 W US 0003776W WO 0048772 A2 WO0048772 A2 WO 0048772A2
Authority
WO
WIPO (PCT)
Prior art keywords
recited
component part
container
coil
conductive container
Prior art date
Application number
PCT/US2000/003776
Other languages
English (en)
Other versions
WO2000048772A3 (fr
Inventor
John P. Barber
David P. Bauer
Duane C. Newman
Edward A. Knoth
Original Assignee
Iap Research, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Iap Research, Inc. filed Critical Iap Research, Inc.
Publication of WO2000048772A2 publication Critical patent/WO2000048772A2/fr
Publication of WO2000048772A3 publication Critical patent/WO2000048772A3/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/087—Compacting only using high energy impulses, e.g. magnetic field impulses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/045—Fixed inductances of the signal type  with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
    • 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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies

Definitions

  • This invention relates to electrical components, such as transformers, chokes and, more particularly, to a method and system for forming particulate or powder-like materials into a unitary, firmly-compacted body of material to provide transformers, chokes, commutators, rotors and/or stators for motors.
  • Powder metal bodies have been formed by means of pressure and heat. Such a method has also been used for forming unitary bodies from other particulate materials.
  • U.S. Patent Nos . 5,405,574; 5,611,139; 5,611,230 and 5,689,797 all disclose systems and methods for compacting powder-like materials.
  • U.S. Patent No. 5,689,797 discloses a method for producing an annular body wherein a container is filled with a particulate material and an electrically conductive drive member is used to induce a current in the container to cause a compaction pressure to be applied to the particulate material. This causes the material to compress and compact within the container into an annular body of magnetic compacted particulate material.
  • U.S. Patent No. 5,611,139 discloses a structure for increasing the density of a powder comprising a support for receiving the powder and an electrically conductive driver positioned adjacent the support and a connector for connecting the driver to a source of electrical energy for energizing the driver to create a magnetic field to pressure the powder, thereby producing an integral part from the powder.
  • Fig. 11 shows a prior art magnetic compaction system having a direct current power supply A to which is connected electrical conductors B and C.
  • a switch D which is also connected to a conductor E.
  • the conductor E and the conductor C have joined there between a capacitor.
  • the conductor E is also connected to a switch G which is also connected a connector H.
  • the conductor C and the conductor H are connected to a solenoid I which encompasses an electrically conductive container I.
  • the switch is closed, and the capacitor F is charged from the power supply A. After the capacitor F is completely charged, the switch D is opened and the switch G is closed.
  • a wall L may closely encompass the energizing solenoid or coil I and restrain the solenoid or coil I against expansion as current flows there through.
  • One problem with the current designs and configurations of ferrite-based transformers is that they tend to be relatively large. Consequently, the costs associated with manufacturing and producing such transformers tends to be relatively high, and reliability is not as good as desired.
  • This invention provides a system and method wherein powder-like and/or particulate materials are received in a container along with a insulated coil and subject to dynamic magnetic compaction to produce a transformer, choke, rotor or stator for an electric motor and the like.
  • the method and related structure of this invention applies pressures generated by non-contact electromagnetic forces. These electromagnetic pressures are generated by employing suitably shaped energizing coils, such as solenoids or the like, which have the necessary capacity.
  • An electrically conductive container is provided wherein a powder-like material and an inner coil is situated therein.
  • An electrical current is passed through a solenoid or energizing coil surrounding the container, and the electrically conductive container is reduced in transversed dimensions, thereby encasing both the particulate material and inner coil to provide a high density body which may be used as a transformer or choke.
  • the compaction of the particulate material is preferably performed by electromagnetic compaction as electrical energy is applied in short time pulses.
  • An object of this invention is to provide a compacted electrical component having improved manufacturing characteristics, reduced cost and improved reliability.
  • Another object of this invention is to provide an electrical component manufactured using dynamic magnetic compaction.
  • this invention comprises a component part comprising a conductive container for receiving a powderous material, an internal coil having an insulating coating situated in the conductive container, the conductive container compacting the powderous material about the internal coil to form the component part when the conductive container is subject to an electromagnetic field.
  • this invention comprises a method of making a component part comprising the steps of providing a conductive container for receiving a powderous material, situating an internal coil having an insulating coating situated in the conductive container, situating a powderous material in the conductive container, energizing the conductive container to magnetically compact the conductive container and the powderous material to provide the component part .
  • this invention comprises a compaction system comprising a power supply, a plurality of conductors coupled to the power supply, an energizing coil for providing an electromagnetic field, at least one capacitor connected across the energizing coil, at least one switch coupled to the plurality of conductors and selectively coupling the power supply to at least one capacitor and at least one switch, the energizing coil be situated relative to a conductive container in order to generate an electromagnetic field to energize a conductive container to magnetically compact a powderous material about an internal coil to form a component part, wherein the internal coil comprises an insulating coating.
  • Fig. 1 is a perspective view of a part prior to compaction in accordance with one embodiment of the invention
  • Fig. 2 is a sectional view of the part shown in Fig. 1;
  • Fig. 3 is a perspective view of the part shown in Fig. 1 after compaction
  • Fig. 4 is a sectional view of the part shown in Fig. 3;
  • Fig. 5 is a perspective view of another part of another embodiment of the invention
  • Fig. 6 is a perspective view of another part of another embodiment of the invention
  • Fig. 7 is a schematic view of a magnetic compaction system in accordance with one embodiment of the invention
  • Fig. 8 is a section view of a bobbin in accordance with one embodiment of the invention
  • Fig. 9 is a sectional view, taken along the line 9-9 in Fig. 2, of a plurality of wires having an insulative coating which comprise the coil;
  • Figs. 10A and 10B are views of wound stators for an electrical motor manufactured in accordance with this invention.
  • Fig. 11 is an illustration of a prior art device .
  • Figs. 1-10 illustrate various embodiments of the invention.
  • a component such as a transformer 10
  • the internal coil 16 has an insulated coating of varnish or other suitable coating.
  • the coil 16 is described as having the insulation mentioned, it should be appreciated that other types of insulation may be utilized.
  • a suitable pliable varnish or other insulation product such as FORMVAR, may be utilized as well.
  • Another example of an alternate coating could be polyimide. The important point is that the coil 16 and each of the wires 16c-16e (Fig. 9) have an insulation 17 to insulate them from the material 14 both during and after compaction.
  • the powder 14 is preferably either a ferrite or iron powder or any other suitable magnetic powder material.
  • the powder 14 is situated in the container 12 and around the coil 16.
  • the container 12, powder 14 and coil 16 are then placed inside another solenoid or energizing coil 18 as shown in Fig. 7.
  • the invention comprises a power supply 20 coupled to the conductors 22 and 24.
  • a switch 26 which is also connected to a conductor 28.
  • the conductor 28 and the conductor 24 have joined there between a capacitor 30.
  • the conductor 28 is also connected to a switch 32 which is also connected to a conductor 34.
  • the conductor 24 and the conductor 34 are connected to the solenoid or energizing coil 18 which encompasses the electrically conductive container 12.
  • the electrically conductive container 12 is shown as being cylindrical in transverse dimension; however, the electrically conductive container 12 may be of any suitable or desired shape and size.
  • the electrically conductive container may be of any suitable, electrically conductive material, such as, for example, silver, aluminum, copper or other conductive material.
  • the switch 26 is closed, and the capacitor 30 is charged from the power supply 20. After the capacitor 30 is completely charged, the switch 26 is opened and the switch 32 is closed.
  • the switch 32 is closed, a large quantity of electrical current flows from the capacitor 30 through the solenoid or coil 36.
  • the electrical current flows through the coil or solenoid 36, magnetic pressure is applied upon the electrically conductive container 38.
  • the pressure acts similarly upon the electrically conductive container 38, and the transverse dimension of the electrically conductive container 38 are reduced.
  • compression occurs within the electrically conductive container, and the powder-like material 14 is compacted and compressed around coil 16.
  • the powderous material 14 becomes a dense body and the container 12, powder 14 and inner coil 16 provide a unitary finished part useful in providing a transformer or choke.
  • the container 12, powder 14 and soil 16 may be placed in a retaining die (not shown) having a top and bottom in support of end 12a and 12b of container 12.
  • the coil 16 has a plurality of leads 16a and 16b which extend outside of end 12a and end 12b, respectively, of container 12.
  • Fig. 5 shows leads 16a and 16b both extending from end 12a of container 12.
  • the invention may comprise more than one inner coil 16, such as the use of multiple coils 40 and 42 which are stacked as shown in Fig. 6 or they could be interlaced or woven so that the turns of each coil are adjacent to each other.
  • the magnetic performance of the powder 14 can be enhanced by using powders which have high inherent bonding characteristics and permeability, such as pure iron powder. Iron powders are preferable because of their inherent binding ability during magnetic compaction. It has been found that the performance of the component 10 can be enhanced by utilizing plastic coated powders, such as EM-1 products available from Quebec Metal Products, Inc. Performance is also enhanced by improving the compacted density of the powder 14.
  • features of the invention described in U.S. Patent Application Serial No. 08/681,898, which is assigned to the same Assignee as the present invention and which is incorporated herein by reference and made apart hereof may be utilized.
  • wire 16 in an octagonal or hexagonal or other cross- sectional shaped facilitates improving the compacted density of part 10 which, in turn, improves performance.
  • powder 14 between the turns of coil 16 may tend to "short circuit" the magnetic periphery of the component 10.
  • a non-magnetic or insulating bobbin 44 (Fig. 8) formed, for example, of plastic. It has also been found that using a non-magnetic filler material 46 between the wires 16c-16e further facilitate preventing any short circuit between or among any of the wires 16c-16e.
  • Another advantage of this compacted powder component design is that it facilitates dissipating heat because the compacted powder 14 conducts the heat away from coil 16.
  • the container 12 (Figs. 1-5) comprises an exemplary dimension of 16mm diameter, but it should be appreciated that smaller or larger components 10 may be made without departing from the features of the invention.
  • the wires 16c-16e which make up coil 16 each have a diameter of about 1mm and are made of copper, and these dimensions may be varied as desired.
  • the dimensions of the finished compacted part 10 are on the order of about 42mm. It should be appreciated, however, that the dimensions and characteristics of the part 10 may be selectively varied depending upon the application.
  • FIG. 10 shows a cross- sectional view of a wound stator 50 having the wires 16 compacted therein to provide a finished stator which, when used with a rotor (not shown) and power supply (not shown) provide an electric motor capable of performing work.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Insulating Of Coils (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention porte sur un transformateur et plus particulièrement sur un système et un procédé de fabrication d'un transformateur recourant à une technique de compaction magnétodynamique comportant les étapes suivantes: mise en place dans une enceinte conductrice d'une bobine et d'un matériau pulvérulent conducteur tel que de la ferrite entourant la bobine et ses spires; alimentation d'un condensateur produisant un puissant courant énergétique dans une deuxième bobine entourant l'enceinte, le matériau pulvérulent et la première bobine, ce qui provoque la compaction de l'enceinte, du matériau pulvérulent et de la bobine . On peut ainsi réaliser un composant électrique tel qu'un transformateur, un moteur, un commutateur, un rotor ou une bobine d'arrêt.
PCT/US2000/003776 1999-02-16 2000-02-15 Appareil et procede de fabrication d'un composant electrique WO2000048772A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12024499P 1999-02-16 1999-02-16
US60/120,244 1999-02-16

Publications (2)

Publication Number Publication Date
WO2000048772A2 true WO2000048772A2 (fr) 2000-08-24
WO2000048772A3 WO2000048772A3 (fr) 2000-12-14

Family

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Family Applications (1)

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PCT/US2000/003776 WO2000048772A2 (fr) 1999-02-16 2000-02-15 Appareil et procede de fabrication d'un composant electrique

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1235324A3 (fr) * 2001-02-27 2004-09-15 Delphi Technologies, Inc. Pressage électromagnétique de fer en poudre pour des applications de noyau de stator
CN105436500A (zh) * 2015-11-11 2016-03-30 湖南大学 一种电磁脉冲径向粉末压实装置和压实方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2966704A (en) * 1957-01-22 1961-01-03 Edward D O'brian Process of making a ferrite magnetic device
DE975730C (de) * 1951-07-04 1962-07-05 Siemens Ag Verfahren zur Herstellung eines magnetischen Massekernes fuer Hochfrequenzspulen
US4696100A (en) * 1985-02-21 1987-09-29 Matsushita Electric Industrial Co., Ltd. Method of manufacturing a chip coil
US5611230A (en) * 1992-02-10 1997-03-18 Iap Research, Inc. Structure and method for compaction of powder-like materials
WO1998006525A2 (fr) * 1996-07-29 1998-02-19 Iap Research, Inc. Structure et procede de compactage de materiaux pulverulents

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE975730C (de) * 1951-07-04 1962-07-05 Siemens Ag Verfahren zur Herstellung eines magnetischen Massekernes fuer Hochfrequenzspulen
US2966704A (en) * 1957-01-22 1961-01-03 Edward D O'brian Process of making a ferrite magnetic device
US4696100A (en) * 1985-02-21 1987-09-29 Matsushita Electric Industrial Co., Ltd. Method of manufacturing a chip coil
US5611230A (en) * 1992-02-10 1997-03-18 Iap Research, Inc. Structure and method for compaction of powder-like materials
WO1998006525A2 (fr) * 1996-07-29 1998-02-19 Iap Research, Inc. Structure et procede de compactage de materiaux pulverulents

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
KONONENKO V V ET AL: "Kinetics of magnetic pulse pressing of iron powder" SOVIET POWDER METALLURGY AND METAL CERAMICS, vol. 13, no. 9, 1975, pages 709-711, XP002144651 *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1235324A3 (fr) * 2001-02-27 2004-09-15 Delphi Technologies, Inc. Pressage électromagnétique de fer en poudre pour des applications de noyau de stator
CN105436500A (zh) * 2015-11-11 2016-03-30 湖南大学 一种电磁脉冲径向粉末压实装置和压实方法

Also Published As

Publication number Publication date
WO2000048772A3 (fr) 2000-12-14

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