US3848331A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of producing molded stators from steel particles
Assignee: AO Smith Corp
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Filing: 1973-09-11
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Granted: 1974-11-19
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Expires: 1993-09-11
Abstract
Abstract A method is disclosed for forming a magnetic core. The core comprises a preformed coil about which a plurality of substantially rectangular microlaminations of a ferromagnetic material are disposed and the components are compressed into a unitary structure. The method includes the steps of preforming a coil assembling the coil in fluid-tight container together with a core bar positioned centrally of the coil. Microlaminations are added to the container which is thereafter pressurized to compress the microlaminations about the coil to form a unitary structure.
Inventors
- 👤 N Pavlik
- 👤 J Cunningham
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 06:30
CPC Classifications
H; H02; H02K; H02K15/00; H02K15/02; H02K1/00; H02K1/06; H02K1/12; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49009; Y10T29/4902; Y10T29/49073; Y10T29/49075; Y10T29/49076
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
122 words
The method of producing a molded core having at least one conductor embedded therein employing microlaminations in which the microlamInations are formed from a ferromagnetic material, are substantially of an elongated rectangular cross-section, have been annealed to decarburize, deoxidize and improve the magnetic characteristics thereof, and in which each of the microlaminations is provided with an electrically insulative coating on the surface thereof, the steps comprising, preforming a conductor into a desired configuration, assembling the preformed conductor in a flexible container of predetermined configuration, adding microlaminations about the conductor within the container, sealing the container, compressing the microlaminates about the conductor to attain a packing factor in excess of 80%, removing the pressure and thereafter removing the molded core from the container.
Claim 2
Independent Claim
122 words
The method of producing a molded core having at least one conductor embedded therein employing microlaminations in which the microlamInations are formed from a ferromagnetic material, are substantially of an elongated rectangular cross-section, have been annealed to decarburize, deoxidize and improve the magnetic characteristics thereof, and in which each of the microlaminations is provided with an electrically insulative coating on the surface thereof, the steps comprising, preforming a conductor into a desired configuration, assembling the preformed conductor in a flexible container of predetermined configuration, adding microlaminations about the conductor within the container, sealing the container, compressing the microlaminates about the conductor to attain a packing factor in excess of 80%, removing the pressure and thereafter removing the molded core from the container.
Claim 3
Dependent Claim
17 words
The method of claim 1 in which the microlaminations are treated with a binder prior to pressurization.
Claim 4
Dependent Claim
31 words
The method of claim 1, in which a core bar of predetermined shape is disposed within the preformed conductor which is disposed in the flexible container prior to introducing the microlaminations.
Claim 5
Dependent Claim
23 words
The method of claim 1 in which the conductor is provided with a conductor-to-microlaminate insulation not in excess of 3 mils in thickness.
Claim 6
Dependent Claim
27 words
The method of claim 1 in which a yoke is applied to the molded core, said yoke being in the form of a tape wound ring core.
Claim 7
Dependent Claim
29 words
The method of claim 1 in which a yoke is applied to the molded core, said yoke being in the form of a plurality of punched or stamped laminations.
Claim 8
Dependent Claim
20 words
The method of claim 1 in which the container is subjected to vibratory energy while the microlaminations are added thereto.
Claim 9
Independent Claim
170 words
The method of producing a molded stator employing microlaminations in which the microlaminations are formed from low carbon steel, are substantially rectangular in shape, have been annealed to decarbonize and deoxidize the same and improve the magnetic characteristics thereof and in which each of the microlaminations is provided with a magnetically insulative coating on the surface thereof, the steps comprising, preforming a stator coil, preforming a stator yoke, said yoke having an outside diameter of the desied dimension of the finished stator and an inside diameter sufficiently great to accommodate the coil therein, assembling the preformed yoke and the the preformed coil in a flexible container of predetermined configuration, said coil being positioned centrally of the yoke and both within the container, positioning a core bar centrally within the coil, energizing the coil, adding the microlaminates about the coil within the container, sealing the container, pressurizing the container to effect a packing factor in excess of about 80%, removing the pressure and thereafter removing the molded stator from the container.
Claim 10
Independent Claim
170 words
The method of producing a molded stator employing microlaminations in which the microlaminations are formed from low carbon steel, are substantially rectangular in shape, have been annealed to decarbonize and deoxidize the same and improve the magnetic characteristics thereof and in which each of the microlaminations is provided with a magnetically insulative coating on the surface thereof, the steps comprising, preforming a stator coil, preforming a stator yoke, said yoke having an outside diameter of the desied dimension of the finished stator and an inside diameter sufficiently great to accommodate the coil therein, assembling the preformed yoke and the the preformed coil in a flexible container of predetermined configuration, said coil being positioned centrally of the yoke and both within the container, positioning a core bar centrally within the coil, energizing the coil, adding the microlaminates about the coil within the container, sealing the container, pressurizing the container to effect a packing factor in excess of about 80%, removing the pressure and thereafter removing the molded stator from the container.
Claim 11
Dependent Claim
17 words
The method of claim 4 in which the microlaminates are coated with a binder prior to pressurization.
Claim 12
Dependent Claim
23 words
The method of claim 4 in which the coil is provided with a wire-to-microlaminations electrical insulation not in excess of about 3 mils.
Claim 13
Dependent Claim
20 words
The method of claim 4 in which the yoke is formed in the manner of a tape wound ring core.
Claim 14
Dependent Claim
19 words
The method of claim 4 in which the yoke is formed of a plurality of stamped or punched laminations.
Claim 15
Independent Claim
151 words
The method of producing a molded core having at least one conductor embedded therein employing microlaminations in which the microlaminations are formed from a ferromagnetic material, are substantially of an elongated rectangle cross section, have been annealed to decarbonize, deoxidize and improve the magnetic characteristics thereof, and in which each of the microlaminations is provided with an electrically insulative coating on the surface thereof, the steps comprising, preforming the conductor into a coil configuration, assembling the preformed coil centrally within a flexible container of predetermined configuration, positioning a core bar in predetermined spaced relation within the coil, adding a predetermined amount of microlaminations to the space between the core bar and container waLls and about the coil, sealing the container, pressurizing the microlaminations and coil to attain a packing factor in excess of 80% to form a unitary structure, removing the pressure and thereafter removing the molded core from the container.
Claim 16
Independent Claim
151 words
The method of producing a molded core having at least one conductor embedded therein employing microlaminations in which the microlaminations are formed from a ferromagnetic material, are substantially of an elongated rectangle cross section, have been annealed to decarbonize, deoxidize and improve the magnetic characteristics thereof, and in which each of the microlaminations is provided with an electrically insulative coating on the surface thereof, the steps comprising, preforming the conductor into a coil configuration, assembling the preformed coil centrally within a flexible container of predetermined configuration, positioning a core bar in predetermined spaced relation within the coil, adding a predetermined amount of microlaminations to the space between the core bar and container waLls and about the coil, sealing the container, pressurizing the microlaminations and coil to attain a packing factor in excess of 80% to form a unitary structure, removing the pressure and thereafter removing the molded core from the container.
Claim 17
Dependent Claim
23 words
The method of claim 9 in which the assembly is subjected to vibratory energy during the addition of the microlaminates to the container.
Claim 18
Dependent Claim
17 words
The method of claim 9 in which the microlaminations are treated with a binder prior to pressurization.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-11-18 | 1978-05-20 | 1978-11-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-11-18 | 1982-05-20 | 1982-11-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-11-18 | 1986-05-20 | 1986-11-19 | $7700.00 | Window Closed / Lapsed |