Inductor insert compositions and methods
First Claim
1. A composition useful in fabricating blocks or inserts for inductors comprising:
- (a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and
(b) about 0.5 percent to about 2 percent of an insulating polymer binder;
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Abstract
Disclosed are compositions useful in fabricating blocks or inserts for inductors comprising:
(a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and
(b) about 0.5 percent to about 2 percent of an insulating polymer binder selected from the group consisting of epoxies, flourocarbon, hot melt adhesives, and mixtures thereof;
wherein said iron powder has a specific surface area of less than about 0.25 m2 /g and a carbon content of less than about 0.01 percent; and
wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 500 KHz. Blocks and inserts made from such compositions, as well as methods of manufacturing such inserts, are also disclosed.
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Citations
24 Claims
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1. A composition useful in fabricating blocks or inserts for inductors comprising:
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(a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating polymer binder; - View Dependent Claims (4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 19)
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2. wherein said iron powder has a specific surface area of less than about 0.25 m2 /g and a carbon content of less than about 0.01 percent;
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3. wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 500 KHz.
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16. A composition useful in fabricating blocks or inserts for inductors comprising:
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(a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating polymer epoxy resin binder; wherein said iron powder has a specific surface area of less than about 0.252 /g and a carbon content of less than about 0.01 percent; and wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 50 KHz. - View Dependent Claims (20)
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17. A composition useful in fabricating blocks or inserts for inductors comprising:
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(a) about 98 percent to about 99.5 percent by weight of a high purity, annealed electrolytically prepared iron powder; and (b) about 0.5 percent to about 2 percent of an insulating flourocarbon polymer binder; wherein said iron powder has a specific surface area of less than about 0.252 /g and a carbon content of less than about 0.01 percent; and wherein said composition after pressing at at least about 30 Tsi demonstrates a maximum of 5 percent regression in permeability and a total core loss of less than about 0.8 to about 1.2 ohms between 10 KHz and 50 KHz.
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18. A method of preparing a block or insert for conductors comprising:
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(a) preparing a premix comprising an evaporable solvent, a polmer binder and a high purity, annealed electrolytically prepared iron powder; (b) substantially drying the product of step (a); (c) forming an insert from said substantially dried composition at a pressure of about 30 to about 50 Tsi; and (d) curing the formed insert at an elevated temperature of about 150 to about 500 degrees F. - View Dependent Claims (21, 22, 23, 24)
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Specification
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Current AssigneeRobert S. Ruffini
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Original AssigneeRobert S. Ruffini
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InventorsRuffini, Robert S.
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Primary Examiner(s)Barr, Josephine
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Application NumberUS07/115,442Time in Patent Office347 DaysField of Search252/513, 252/519, 523/442, 523/458, 523/451, 524/417, 524/440, 336/233, 29/348US Class Current252/513CPC Class CodesC08K 3/08 MetalsH01F 1/26 by macromolecular organic s...H05B 6/365 using supplementary conduct...
