WO2004109724A1 - Soft-metal electromechanical component and method making same - Google Patents
Soft-metal electromechanical component and method making same Download PDFInfo
- Publication number
- WO2004109724A1 WO2004109724A1 PCT/IB2004/050830 IB2004050830W WO2004109724A1 WO 2004109724 A1 WO2004109724 A1 WO 2004109724A1 IB 2004050830 W IB2004050830 W IB 2004050830W WO 2004109724 A1 WO2004109724 A1 WO 2004109724A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- toroid
- milling
- adhesive
- soft magnetic
- magnetic metal
- Prior art date
Links
Classifications
-
- 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
- H01F41/0213—Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
- H01F41/0226—Manufacturing of magnetic circuits made from strip(s) or ribbon(s) from amorphous ribbons
-
- 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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/04—Cores, Yokes, or armatures made from strips or ribbons
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/02—Details of the magnetic circuit characterised by the magnetic material
-
- 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
- Multi-pole rotating electro-mechanical devices such as motors, generators, re- gen motors, alternators, brakes and magnetic bearings are comprised of rotors and electromechanical components.
- AC motors rotate by producing a rotating magnetic field pattern in the electro-mechanical component that causes the rotor to follow the rotation of this field pattern.
- the frequency varies, the speed of the rotor varies.
- the frequency of the input source must be increased.
- High frequency motors manufactured with the proper materials can be very efficient. For certain applications, like electric or hybrid cars, highly efficient electric motors are desirable.
- electro-mechanical components for high frequency electric motors and generators is problematic. Iron or steel components are quite common in electric motors and generators. However, at high frequencies, such as those greater than 400Hz, conventional iron or steel components are no longer practical. The high frequency of the AC source increases the core losses of the iron or steel components, reducing the overall efficiency of the motor. Additionally, at very high frequencies, the component may become extremely hot, cannot be cooled by any reasonably acceptable means and may cause motor failure.
- soft magnetic ribbon For construction of electro-mechanical components used in high frequency electric motors, ribbon made from soft magnetic material provides distinct advantages.
- soft magnetic ribbon materials would be either 1) conventional material typically defined as .008" and thicker, non grain oriented with a typical Si content of 3%+/- l A% or 2) alternate soft materials that are .007" or thinner with Si content of 3% to 7%, amorphous, or nanocrystalline alloys and other grain oriented or non grain oriented alloys.
- Some soft magnetic ribbon materials exhibit inherent characteristics that make their use in high frequency electro-mechanical rotating devices highly desirable. Some soft magnetic ribbons are easy to magnetize and demagnetize, which means an electro-mechanical component made with these metals would have low power loss, low temperature rise at high frequency, extremely fast magnetization and easy conversion of electrical to mechanical energy. An electro-mechanical component made of such an metal would generate less core losses and be able to operate at much higher frequencies, resulting in motors and generators of exceptional efficiency and power density.
- Soft magnetic materials are commercially produced as ribbon or strip.
- a preferred example of a soft magnetic metal ribbon is Metglas®, which is an amorphous material, manufactured by Honeywell, Inc.
- Soft magnetic metal ribbons are very thin and of varying width. Manufacturing components of soft magnetic metal ribbon requires winding the soft magnetic ribbon into a shape and then heat processing the shape. Simple three dimensional shapes, such as toroids, can currently be constructed from soft magnetic metal ribbon.
- electro-mechanical components are often not simple three dimensional shapes.
- the electro-mechanical component can have numerous slots for accommodating motor coils in a generally toroidal structure.
- a method for forming a three dimensional soft magnetic metal mass suitable for milling consists of wrapping soft magnetic metal ribbon into a three dimensional shape , then applying adhesive to the three dimensional shape. The adhesive is then cured and the cured form is mechanically constrained in three dimensions. The method results in an soft magnetic metal mass which can withstand the mechanical stresses of machining.
- the three dimensional soft magnetic metal form can be milled using a horizontal mill, a vertical mill, a computer numeric control (CNC) machine, or any other common milling equipment.
- CNC computer numeric control
- the ability to create three dimensional soft magnetic metal shapes allows the use of soft magnetic metal for a variety of applications heretofore foreclosed by the mechanical characteristics of soft magnetic metal ribbon.
- soft magnetic metal ribbon is wound into a toroid.
- the toroid is then placed in a milling assembly.
- Adhesive is applied to the toroid, and then cured.
- the toroid is then milled into an electro-mechanical component shape, and then thermally processed into a electro-mechanical component.
- FIG. 1 shows a soft magnetic metal ribbon being wound on an inner ring.
- FIG. 2 shows an inner containment hat.
- FIG. 3 shows an outer containment hat.
- FIG. 4 shows a milling assembly
- FIG. 5 shows a milling assembly being milled.
- FIG. 6 shows a soft magnetic metal electro-mechanical component. DETAILED DESCRIPTION OF THE DRAWINGS
- FIG. 1 shows soft magnetic metal ribbon 10 being wound about a winding axis 11 on an inner ring 14.
- Winding machine 13 contains soft magnetic metal ribbon roll 12.
- Inner ring 14 is placed on winding plate 16.
- Soft magnetic metal ribbon 10 is wound on inner ring 14, forming soft magnetic metal toroid 18.
- Soft magnetic metal toroid 18 has an inner side surface 15, an outer side surface 17, a top 19, and a bottom 21.
- FIG. 1 shows the formation of an soft magnetic metal toroid 18, it will be appreciated that a three dimensional shape could be created with a geometry distinctly different from the soft magnetic metal toroid 18. For example, it would be possible by winding around four corners to create a rectangular prism.
- Soft magnetic metal ribbon 10 can be wound using a variety of machines and methods. Preferably, a consistent, firm toroid will have at least an 85% wind density compared to the inherent ribbon density. Soft magnetic metal toroid 18 is then removed from winding plate 16. Soft magnetic metal ribbon 10 can be wound around the inner ring 14 while attached to the inner containment hat 20 as a single unit.
- An adhesive is then applied to the soft magnetic ribbon toroid 18 in a manner to permeate the soft magnetic metal toroid 18.
- Inner ring 14 is still contained within the soft magnetic ribbon toroid 18.
- a suitable adhesive is Scotch Cast adhesive by 3M, diluted by acetone so as to achieve about a 20% mix by volume.
- the adhesive is applied to soft magnetic ribbon toroid 18 by an ambient atmospheric soak process.
- Soft magnetic ribbon toroid 18 is immersed in the adhesive until the adhesive infiltrates the layers.
- the adhesive could be applied by immersing soft magnetic ribbon toroid 18 into the adhesive inside a vessel that is evacuated of air. The vacuum created would enhance the infiltration of the adhesive into the soft magnetic ribbon toroid 18 layers.
- Adhesive could also be applied to the soft magnetic ribbon during the winding process utilizing a wet spray or dry electrolytic deposition process.
- Alternative resins, epoxies or adhesives may be used. Different brands as well as different types of resins, epoxies or adhesives may be used. Heat cured epoxies that require various temperatures as well a two stage epoxies that cure at room temperature would also be suitable.
- soft magnetic ribbon toroid 18 After soft magnetic ribbon toroid 18 is sufficiently infiltrated with adhesive, soft magnetic ribbon toroid 18 is allowed to drain. Once dry, soft magnetic ribbon toroid 18 is placed inside an oven for curing.
- the temperature for heat treating the adhesive be a fraction of the temperature for heat processing soft magnetic metal ribbon 10. A preferable fraction is V-, although fractions of Vt and % might also be satisfactory.
- FIG. 2 shows inner containment hat 20.
- Inner containment hat 20 is a cylinder comprised of a number of columns 22 extending upward from the inner containment hat base 24. Fingers 26 extend outward from columns 22 at approximately a right angle. Fingers 26 increase in width as they extend further from the columns 22. Fingers 26 are arranged in a circle, forming an annulus 28. The columns 22 and fingers 26 form a plurality of inner containment hat grooves 29. Columns 22 of inner containment hat 20 are placed inside inner ring 14.
- the height of columns 22 is approximately equal to the height of the soft magnetic metal toroid 18.
- the diameter of the soft magnetic metal toroid 18 is about equal to the diameter of the annulus 28.
- Outer containment hat 30 is cylindrical, with a base 32. Bars 34 extend upward from base 32. At the top of each bar 34 is a lug 36 extending inward. Lug 36 for each bar 34 forms a flange for securing the amorphous metal toroid 18 within outer containment hat 30. Bars 34 and lugs 36 form a plurality of outer containment hat grooves 38.
- Milling assembly 40 shown in FIG. 4, is then fonned.
- Soft magnetic metal toroid 18, still containing inner ring 14, along with the inner containment hat 20 is placed within outer containment hat 30. Lugs 36 and fingers 26 are aligned.
- Milling assembly 40 contains the soft magnetic metal toroid 18 within a toroidal geometry.
- soft magnetic metal toroid 18 could be placed within outer containment hat 30 and inner containment hat 20 prior to treatment with the adhesive.
- the soft magnetic metal toroid 18 After application of the adhesive and placement within the mechanical constraints of the inner ring 14, inner containment hat 20, and outer containment hat 30, the soft magnetic metal toroid 18 has sufficient structural integrity to withstand the stresses of milling.
- Milling plate 44 is placed on the bottom of the soft magnetic metal toroid 18. Milling plate 44 could be the same as winding plate 16.
- Soft magnetic metal toroid 18 having been treated with an adhesive, is thus firmly contained within a structure, allowing soft magnetic metal toroid 18 to be milled and formed in three dimensions. Complex shapes can thus be constructed from the metal ribbon toroid 18, allowing structures such as electro-mechanical components to be made from the soft magnetic metal toroid 18. As illustrated by FIG. 5, milling assembly 40 is placed in mill 50. Mill 50 could be a horizontal mill, a vertical mill, a CNC machine, or any other type of mill.
- mill 50 should preferably have the axis of rotation of the mill tools 52 perpendicular to the axis of the soft magnetic metal toroid 18.
- the depth and width of the slots milled into the soft magnetic metal toroid 18 can be finely controlled.
- Mill 50 cuts slots or other geometries into the soft magnetic metal toroid 18.
- Inner ring 14, in conjunction with the epoxy, does not allow strips of soft magnetic metal ribbon 10 to separate during machining, thereby producing clean and accurate cuts.
- milling assembly 40 is removed from mill 50.
- Milling assembly 50 is then thermally processed in accordance with the recommendations of the manufacturer of soft magnetic metal ribbon 10 as required. If the amorphous metal ribbon 10 is Metglas®, thermal processing consists of placing milling assembly 50 into a vacuum furnace at 695 degrees Fahrenheit for approximately sixty minutes. Some soft magnetic ribbon materials require thermal processing to achieve the desired magnetic properties while others require thermal processing to properly relieve the stresses in the milled electro-mechanical component shape as a result of the milling process. It is conceivable that, given proper mechanical containment during milling, some materials that do not require thermal processing for magnetic properties could forego the thermal processing.
- the milling assembly 40 is disassembled by removing retainer 42, outer containment 30, inner containment hat 20, and inner ring 14.
- Soft magnetic metal toroid 18 has thus been made into an soft magnetic metal electromechanical component 60, shown in FIG. 6.
- the method as described allows for the creation of three dimensional forms from soft magnetic metal ribbon.
- the applications for such three dimensional forms could be as electro-mechanical components for a variety of machines.
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Manufacture Of Motors, Generators (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
- Adhesives Or Adhesive Processes (AREA)
- General Electrical Machinery Utilizing Piezoelectricity, Electrostriction Or Magnetostriction (AREA)
Abstract
Description
Claims
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN2004800232183A CN1839451B (en) | 2003-06-11 | 2004-06-02 | Method for making soft magnetic amorphous electromagnetic component |
AU2004246416A AU2004246416B2 (en) | 2003-06-11 | 2004-06-02 | Soft-metal electromechanical component and method making same |
EP04735776A EP1634310A1 (en) | 2003-06-11 | 2004-06-02 | Soft-metal electromechanical component and method making same |
JP2006516640A JP4773344B2 (en) | 2003-06-11 | 2004-06-02 | Soft metal electromechanical elements and how to make them |
BRPI0411357-8A BRPI0411357A (en) | 2003-06-11 | 2004-06-02 | method of fabricating a low carbon magnetic metal electromechanical component and a low carbon magnetic metal electromechanical component |
MXPA05013540A MXPA05013540A (en) | 2003-06-11 | 2004-06-02 | Soft-metal electromechanical component and method making same. |
CA2529200A CA2529200C (en) | 2003-06-11 | 2004-06-02 | Soft-metal electromechanical component and method making same |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/458,944 | 2003-06-11 | ||
US10/458,944 US7018498B2 (en) | 2003-06-11 | 2003-06-11 | Product and method for making a three dimensional amorphous metal mass |
US10/763,728 US7395596B2 (en) | 2003-06-11 | 2004-01-23 | Process of manufacturing a soft magnetic metal electromechanical component |
US10/763,728 | 2004-01-23 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2004109724A1 true WO2004109724A1 (en) | 2004-12-16 |
WO2004109724B1 WO2004109724B1 (en) | 2005-04-21 |
Family
ID=33513896
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IB2004/050830 WO2004109724A1 (en) | 2003-06-11 | 2004-06-02 | Soft-metal electromechanical component and method making same |
Country Status (7)
Country | Link |
---|---|
EP (1) | EP1634310A1 (en) |
KR (1) | KR100830621B1 (en) |
AU (1) | AU2004246416B2 (en) |
BR (1) | BRPI0411357A (en) |
CA (1) | CA2529200C (en) |
MX (1) | MXPA05013540A (en) |
WO (1) | WO2004109724A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2008545367A (en) * | 2005-06-30 | 2008-12-11 | ライト・エンジニアリング・インコーポレーテッド | Soft magnetic amorphous electromagnetic component and method of manufacturing the same |
WO2018206312A1 (en) * | 2017-05-11 | 2018-11-15 | Robert Bosch Gmbh | Rotor and electrical machine |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7230361B2 (en) | 2003-01-31 | 2007-06-12 | Light Engineering, Inc. | Efficient high-speed electric device using low-loss materials |
Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2293951A (en) | 1939-09-20 | 1942-08-25 | Westinghouse Electric & Mfg Co | Induction apparatus and method of core construction therefor |
GB597218A (en) | 1941-11-07 | 1948-01-21 | Westinghouse Electric Int Co | Improvements in or relating to resinous electrically insulating compositions and to electrical apparatus impregnated therewith |
US2495167A (en) | 1945-05-19 | 1950-01-17 | Westinghouse Electric Corp | Wound core |
US2554262A (en) | 1945-03-15 | 1951-05-22 | Westinghouse Electric Corp | Laminated metal |
US3401287A (en) * | 1966-05-02 | 1968-09-10 | Trw Inc | Variable reluctance dynamoelectric machines |
JPS56104425A (en) * | 1980-01-24 | 1981-08-20 | Matsushita Electric Ind Co Ltd | Formation of amorphous magnetic alloy |
US4621248A (en) * | 1983-06-16 | 1986-11-04 | Tdk Corporation | Amorphous cut core |
DE4030124A1 (en) | 1990-09-24 | 1992-03-26 | Ant Nachrichtentech | Mfg. coil core for inductive component - winding wound strip of permeable material into toroidal core, impregnating with resin and forming slit in core |
US6462456B1 (en) | 1998-11-06 | 2002-10-08 | Honeywell International Inc. | Bulk amorphous metal magnetic components for electric motors |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3543482A1 (en) * | 1985-12-09 | 1987-06-11 | Siemens Ag | METHOD AND DEVICE FOR MANUFACTURING A RING-SHAPED ACTIVE PART FROM A FERROMAGNETIC TAPE AND FRONTLY GROOVED FOR AN ELECTRICAL AXIAL FIELD MACHINE |
-
2004
- 2004-06-02 WO PCT/IB2004/050830 patent/WO2004109724A1/en active Application Filing
- 2004-06-02 EP EP04735776A patent/EP1634310A1/en not_active Withdrawn
- 2004-06-02 CA CA2529200A patent/CA2529200C/en not_active Expired - Fee Related
- 2004-06-02 KR KR1020057024132A patent/KR100830621B1/en not_active IP Right Cessation
- 2004-06-02 BR BRPI0411357-8A patent/BRPI0411357A/en not_active IP Right Cessation
- 2004-06-02 AU AU2004246416A patent/AU2004246416B2/en not_active Ceased
- 2004-06-02 MX MXPA05013540A patent/MXPA05013540A/en active IP Right Grant
Patent Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2293951A (en) | 1939-09-20 | 1942-08-25 | Westinghouse Electric & Mfg Co | Induction apparatus and method of core construction therefor |
GB597218A (en) | 1941-11-07 | 1948-01-21 | Westinghouse Electric Int Co | Improvements in or relating to resinous electrically insulating compositions and to electrical apparatus impregnated therewith |
US2554262A (en) | 1945-03-15 | 1951-05-22 | Westinghouse Electric Corp | Laminated metal |
US2495167A (en) | 1945-05-19 | 1950-01-17 | Westinghouse Electric Corp | Wound core |
US3401287A (en) * | 1966-05-02 | 1968-09-10 | Trw Inc | Variable reluctance dynamoelectric machines |
JPS56104425A (en) * | 1980-01-24 | 1981-08-20 | Matsushita Electric Ind Co Ltd | Formation of amorphous magnetic alloy |
US4621248A (en) * | 1983-06-16 | 1986-11-04 | Tdk Corporation | Amorphous cut core |
DE4030124A1 (en) | 1990-09-24 | 1992-03-26 | Ant Nachrichtentech | Mfg. coil core for inductive component - winding wound strip of permeable material into toroidal core, impregnating with resin and forming slit in core |
US6462456B1 (en) | 1998-11-06 | 2002-10-08 | Honeywell International Inc. | Bulk amorphous metal magnetic components for electric motors |
Non-Patent Citations (2)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 0051, no. 79 (E - 082) 17 November 1981 (1981-11-17) * |
See also references of EP1634310A1 * |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2008545367A (en) * | 2005-06-30 | 2008-12-11 | ライト・エンジニアリング・インコーポレーテッド | Soft magnetic amorphous electromagnetic component and method of manufacturing the same |
JP2012186999A (en) * | 2005-06-30 | 2012-09-27 | Light Engineering Inc | Method for making soft magnetic metal electromagnetic component |
JP2015047065A (en) * | 2005-06-30 | 2015-03-12 | ライト・エンジニアリング・インコーポレーテッド | Method for making soft magnetic metal electromagnetic component |
WO2018206312A1 (en) * | 2017-05-11 | 2018-11-15 | Robert Bosch Gmbh | Rotor and electrical machine |
CN110582924A (en) * | 2017-05-11 | 2019-12-17 | 罗伯特·博世有限公司 | Rotor and motor |
Also Published As
Publication number | Publication date |
---|---|
CA2529200A1 (en) | 2004-12-16 |
WO2004109724B1 (en) | 2005-04-21 |
AU2004246416B2 (en) | 2010-08-26 |
KR100830621B1 (en) | 2008-05-21 |
CA2529200C (en) | 2010-11-09 |
KR20060080537A (en) | 2006-07-10 |
MXPA05013540A (en) | 2006-03-09 |
AU2004246416A1 (en) | 2004-12-16 |
BRPI0411357A (en) | 2006-07-11 |
EP1634310A1 (en) | 2006-03-15 |
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