BULK AMORPHOUS METAL INDUCTIVE DEVICE
First Claim
1. An inductive device, comprising:
- a. a magnetic core that includes a plurality of low-loss bulk ferromagnetic amorphous metal magnetic components assembled in juxtaposed relationship and forming at least one magnetic circuit;
b. securing means for securing said components in said relationship;
c. at least one electrical winding encircling at least a portion of said magnetic core;
d. each of said components comprising a plurality of substantially similarly shaped, planar layers of amorphous metal strips bonded together with an adhesive agent to form a polyhedrally shaped part having a thickness and a plurality of mating faces, the thickness of each of said components being substantially equal;
e. said components being disposed in said assembly with said layers of said strips of each of said components in substantially parallel planes and with each of said mating faces proximate a mating face of another of said components; and
f. said inductive device, having a core-loss less than about 12 W/kg when operated at an excitation frequency “
f”
of 5,000 Hz to a peak induction level “
Bmax”
of 0.3 T.
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Accused Products
Abstract
A bulk amorphous metal inductive device comprises a magnetic core having plurality of low-loss bulk ferromagnetic amorphous metal magnetic components assembled in juxtaposed relationship to form at least one magnetic circuit and secured in position, e.g. by banding or potting. The device has one or more electrical windings and may be used as a transformer or inductor in an electronic circuit. Each component comprises a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhedrally shaped part. The low core losses of the device, e.g. a loss of at most about 12 W/kg when excited at a frequency of 5 kHz to a peak induction level of 0.3 T, make it especially useful for application in power conditioning circuits operating in switched mode at frequencies of 1 kHz or more. Air gaps are optionally interposed between the mating faces of the constituent components of the device to enhance its energy storage capacity for inductor applications. The inductive device is easily customized for specialized magnetic applications, e.g. for use as a transformer or inductor in power conditioning electronic circuitry employing switch-mode circuit topologies and switching frequencies ranging from 1 kHz to 200 kHz or more.
86 Citations
37 Claims
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1. An inductive device, comprising:
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a. a magnetic core that includes a plurality of low-loss bulk ferromagnetic amorphous metal magnetic components assembled in juxtaposed relationship and forming at least one magnetic circuit;
b. securing means for securing said components in said relationship;
c. at least one electrical winding encircling at least a portion of said magnetic core;
d. each of said components comprising a plurality of substantially similarly shaped, planar layers of amorphous metal strips bonded together with an adhesive agent to form a polyhedrally shaped part having a thickness and a plurality of mating faces, the thickness of each of said components being substantially equal;
e. said components being disposed in said assembly with said layers of said strips of each of said components in substantially parallel planes and with each of said mating faces proximate a mating face of another of said components; and
f. said inductive device, having a core-loss less than about 12 W/kg when operated at an excitation frequency “
f”
of 5,000 Hz to a peak induction level “
Bmax”
of 0.3 T. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A method of constructing an inductive device having a core that includes a plurality of ferromagnetic bulk amorphous metal magnetic components, each component having a plurality of layers of amorphous metal strip bonded together with an adhesive agent to form a generally polyhedral part having a thickness and a plurality of mating faces, the method comprising the steps of:
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a. encircling at least one of said magnetic components with an electrical winding;
b. positioning said components in juxtaposed relationship to form said core having at least one magnetic circuit, the layers of each component lying in substantially parallel planes; and
c. securing said components in said juxtaposed relationship. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34)
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35. An electronic circuit device having at least one low-loss inductive device selected from the group consisting of transformers, autotransformers, saturable reactors, and inductors, the device comprising:
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a. a magnetic core that includes a plurality of low-loss bulk ferromagnetic amorphous metal magnetic components assembled in juxtaposed relationship and forming at least one magnetic circuit, each of said components comprising a plurality of substantially similarly shaped, planar layers of amorphous metal strips bonded together with an adhesive agent to form a polyhedrally shaped part having a thickness and a plurality of mating faces, the thickness of each of said components being substantially equal;
b. securing means for securing said components in said relationship wherein said components are disposed with said layers of said strips of each of said components in substantially parallel planes and with each of said mating faces proximate a mating face of another of said components; and
c. at least one electrical winding encircling at least a portion of said magnetic core. - View Dependent Claims (36)
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37. A power conditioning circuit device selected from the group consisting of switch mode power supplies and switch mode voltage converters, the device comprising:
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a. a magnetic core comprising a plurality of low-loss bulk ferromagnetic amorphous metal magnetic components assembled in juxtaposed relationship and forming at least one magnetic circuit, each of said components comprising a plurality of substantially similarly shaped, planar layers of amorphous metal strips bonded together with an adhesive agent to form a polyhedrally shaped part having a thickness and a plurality of mating faces, the thickness of each of said components being substantially equal;
b. securing means for securing said components in said relationship wherein said components are disposed with said layers of said strips of each of said components in substantially parallel planes and with each of said mating faces proximate a mating face of another of said components; and
c. at least one electrical winding encircling at least a portion of said magnetic core.
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Specification