Formable composite magnetic flux concentrator and method of making the concentrator
First Claim
1. A method of making a formable composite magnetic flux concentrator, comprising the steps of:
- (a) preparing a body in a formable putty-like state by mixing together a ferromagnetic material and a binder, said ferromagnetic material being in a percent by weight in the range of about 65% to 90% and said binder being in a percent by weight range of about 35% to 10%;
(b) shaping said body while in said formable putty-like state into a selected shape; and
(c) solidifying said formable body by applying heat to said body to cause said binder to change said formable body having the selected shape to a solid body.
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Abstract
A formable composite magnetic flux concentrator material is composed of about 65% to 90% ferromagnetic material, such as iron powder, and about 35% to 10% binder, the binder being a mixture of an epoxy and one or more catalysts. The concentrator material is provided in a formable state as a putty-like body which can be worked into any desired shape dictated by the configuration of the induction heating coil used in a particular application. In one form, the density of the concentrator material is increased by application of vibration, compression and vacuum to de-air the material and to reduce voids therein. In another form, the iron powder comprises spherical-shaped particles and non-spherical shaped powders chosen in a ratio to maximize the density of material available.
64 Citations
21 Claims
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1. A method of making a formable composite magnetic flux concentrator, comprising the steps of:
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(a) preparing a body in a formable putty-like state by mixing together a ferromagnetic material and a binder, said ferromagnetic material being in a percent by weight in the range of about 65% to 90% and said binder being in a percent by weight range of about 35% to 10%; (b) shaping said body while in said formable putty-like state into a selected shape; and (c) solidifying said formable body by applying heat to said body to cause said binder to change said formable body having the selected shape to a solid body. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method comprising steps of:
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providing a formable magnetic flux concentrator material; forming the concentrator material at low pressure so that there is no loss of desirable magnetic properties; and baking the formable concentrator material to harden the concentrator material into a permanent shape. - View Dependent Claims (12, 13, 14, 15, 16)
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17. A method comprising steps of:
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mixing a formable magnetic flux concentrator material including at least about 85% machineable iron powder; forming the concentrator material at less than 10 tons per square inch; machining the formed concentrator material after the step of forming; and hardening the formed composite material. - View Dependent Claims (18, 19)
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20. A method for forming a magnetic flux concentrator comprising steps of:
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selecting particles of predetermined size comprising an alloy having a selected permeability; mixing a formable magnetic composite material including the alloy particles; forming the formable magnetic composite material at a pressure below about 10 tons per square inch and which is low enough to prevent undesired loss of magnetic properties below the selected permeability; and hardening the formed material. - View Dependent Claims (21)
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Specification