Structures utilizing a structured magnetic material and methods for making

Patent metadata

Field	Value
Publication number	US-11180841-B2
Application number	US-202016744382-A
Country	US
Kind code	B2
Filing date	Jan 16, 2020
Priority date	Sep 30, 2013
Publication date	Nov 23, 2021
Grant date	Nov 23, 2021

Abstract

A soft magnetic material comprises a plurality of iron-containing particles and an insulating layer on the iron-containing particles, the insulating layer comprising an oxide. The soft magnetic material is an aggregate of permeable micro-domains separated by insulation boundaries.

First claim

What is claimed is:

1. A method, comprising:
providing a plurality of iron-aluminum alloy particles;
heating the iron-aluminum alloy particles to a temperature that is below the melting point of the iron-aluminum alloy particles but sufficiently high enough to soften the iron-aluminum alloy particles;
thermally spraying the iron-aluminum alloy particles;
causing the iron-aluminum alloy particles to oxidize to form insulating layers thereon, wherein the insulating layers are insulation boundaries;
depositing the iron-aluminum alloy particles onto a substrate to form an aggregate of permeable micro-domains separated by the insulation boundaries;
subsequently building up a bulk quantity of the iron-aluminum alloy particles on the substrate and on successive layers of the iron-aluminum alloy particles deposited on the substrate such that the aggregate of micro-domains comprises successive micro-domains forming the successive layers of deposited iron-aluminum alloy particles; and
heat treating the bulk quantity of the iron-aluminum alloy particles;
wherein particles defined by the iron-aluminum alloy particles and the insulating layers on the iron-aluminum alloy particles are arranged to form a densely packed solid layer in which a particle in the formed successive layer is substantially spherical on a top side of the particle and is adhered to, in contact with, and takes the shape of a particle in the formed preceding layer at a point of contact of a bottom side of the particle in the successive layer with the particle in the preceding layer;
wherein the micro-domains formed from the particles exhibit isotropy in three dimensions; and
wherein the particles of the micro-domains are substantially completely surrounded by insulation boundaries.

2. The method of claim 1 , wherein the iron-aluminum alloy particles comprise an alloy having a composition of about 89 wt. % iron, about 10 wt. % aluminum, and about 0.25 wt. % carbon.

3. The method of claim 2 , wherein heating the iron-aluminum alloy particles comprises heating to less than about 1450 degrees C.

4. The method of claim 1 , wherein thermally spraying the iron-aluminum alloy particles comprises gas-atomizing the iron-aluminum alloy particles in a carrier gas.

5. The method of claim 1 , wherein thermally spraying the iron-aluminum alloy particles comprises using a high velocity air fuel system in which a carrier gas operates at about 900 degrees C. to about 1200 degrees C. to gas-atomize the iron-aluminum alloy particles.

6. The method of claim 1 , wherein thermally spraying the iron-aluminum alloy particles comprises using a high velocity oxy fuel system operating at about 1400 degrees C. to about 1600 degrees C. to deposit the iron-aluminum alloy particles as a thin coating.

7. The method of claim 1 , wherein thermally spraying the iron-aluminum alloy particles comprises using a low energy plasma spray.

8. The method of claim 1 , wherein causing the iron-aluminum alloy particles to oxidize comprises forming alumina on outer surfaces of the iron-aluminum alloy particles.

Assignees

• Persimmon Technologies Corp
• Persimmon Tech Corporation

Inventors

• Hosek Martin
• Sah Sripati
• Krishnasamy Jayaraman

Classifications

• B22F1/16

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• C23C4/08 Primary

  containing only metal elements (C23C4/073 takes precedence) · CPC title

• H01F1/33

  mixtures of metallic and non-metallic particles; metallic particles having oxide skin · CPC title

• C23C4/129

  Flame spraying · CPC title

• H01F1/24

  the particles being insulated · CPC title