METHOD TO MAKE IMPROVED ELECTRICAL STEELS
An electrical core has a ferromagnetic material having discrete particles, the particles aligned in a unified crystallographic direction, a structural material holding the ferromagnetic material having the shape of a hollow rectangle, and a winding comprised of wires wound around the hollow rectangle to form a core. A method of producing an electrical core includes printing ferromagnetic particles in a shape of an electrical core, aligning the ferromagnetic particles to a unified crystallographic direction to produce aligned particles, depositing a structural material around the aligned particles to form a monolith with a center opening, and applying winding to finish the electrical core.
1 . An electrical core, comprising:
a ferromagnetic material having discrete particles, the particles aligned in a unified crystallographic direction;
a structural material holding the ferromagnetic material having the shape of a hollow rectangle; and
a winding comprised of wires wound around the hollow rectangle to form a core.
2 . The electrical core as claimed in claim 1 , wherein the electrical core has holes arranged in hollow rectangle to accommodate the wires.
3 . The electrical core as claimed in claim 1 , wherein the electrical core has grooves to accommodate the wires.
4 . The electrical core as claimed in claim 1 , wherein the structural material comprises aluminum.
5 . The electrical core as claimed in claim 1 , wherein the structural material comprises a polymer binder.
6 . The electrical core as claimed in claim 1 , wherein the structural material comprises aluminum.
7 . The electrical core as claimed in claim 1 , wherein the particles comprise one of iron, iron silicide, and iron silicon aluminum.
8 . A method of producing an electrical core, comprising:
printing ferromagnetic particles in a shape of an electrical core;
aligning the ferromagnetic particles to a unified crystallographic direction to produce aligned particles;
depositing a structural material around the aligned particles to form a monolith with a center opening; and
applying winding to finish the electrical core.
9 . The method as claimed in claim 8 , wherein printing the ferromagnetic particles and aligning the ferromagnetic particles occurs one of simultaneously, printing and then aligning, and aligning and then printing.
10 . The method as claimed in claim 8 , wherein depositing the structural material comprises one of die casting, printing, or extruding the structural material.
11 . The method as claimed in claim 8 , wherein depositing the structural material comprises printing the structural material in a matrix around the aligned particles.
12 . The method as claimed in claim 11 , wherein printing the structural material comprises printing an aluminum matrix around the aligned particles.
13 . The method as claimed in claim 8 , where in depositing the structural material comprises die casting the structural material and using a negative die to leave grooves in a surface of the structural material.
14 . The method as claimed in claim 8 , wherein depositing the structural material comprises depositing the structural material such that holes are left in the structural material.
15 . The method as claimed in claim 8 , wherein depositing the structural material comprises one of printing or die casting a polymer binder
16 . The method as claimed in claim 8 , wherein applying winding comprises winding wire around the monolith and through the center opening.
17 . The method as claimed in claim 8 , wherein applying winding comprises winding wire around the monolith and through the center opening such that the wires lay in grooves in at least a top surface of the monolith.
18 . The method as claimed in claim 8 , wherein applying winding comprises winding wire through holes in the monolith.