Powdered iron core magnetic devices
First Claim
1. A magnetic core comprising densely packed iron particles having a coating of an alkali metal silicate insulating material and an overcoating of a polymer film selected from the group consisting of silicones, polyimides, fluorocarbons and acrylics, said coating and overcoating providing substantial insulation between particles.
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Accused Products
Abstract
A compacted powdered iron core utilizes iron powder in the 0.002 to 0.006 mean particle size range which is first coated with an alkali metal silicate and then overcoated with a silicone resin polymer. The treated powder is compressed to approximately 94% of theoretical density and then annealed at approximately 600° C. This results in a core component characterized by overall core losses as low as in conventional laminated cores in A.C. operation.
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Citations
20 Claims
- 1. A magnetic core comprising densely packed iron particles having a coating of an alkali metal silicate insulating material and an overcoating of a polymer film selected from the group consisting of silicones, polyimides, fluorocarbons and acrylics, said coating and overcoating providing substantial insulation between particles.
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5. A compacted powdered iron magnetic core component for use in A.C. electrical devices comprising:
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iron powder consisting of particles sized less than 0.05 inch prior to compaction, the particles of said powder having been coated with alkali metal silicate, overcoated with a polymer film selected from the group consisting of silicones, polyimides, fluorocarbons and acrylics providing insulation between particles, and compacted to at least 90% of theoretical iron density, and the so formed compact having been annealed after said compaction and exhibiting relatively low hysteresis losses together with relatively low eddy current losses. - View Dependent Claims (6, 7, 8, 9)
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10. A method of making a powdered iron magnetic core component for use in A.C. electrical devices comprising:
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selecting iron powder having particles sized less than 0.05 inch in diameter, mixing an aqueous solution of alkali metal silicate into said powder, drying the powder, mixing a silicone resin dissolved in an organic solvent into said powder, drying the powder to allow the resin to form a thin overcoat on the particles, and pressing the powder to the desired shape for the core component. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification