Abstract: A high-density stator core for use in electrodynamic devices is fabricated by the electromagnetic pressing of an iron-based powder coated with a dielectric material and methods for performing the electromagnetic pressing are disclosed. The stator core includes a yoke portion that may further include a plurality of integral poles extending either radially outward from an outer circumferential surface of the yoke portion or radially inward from an interior circumferential surface of the yoke portion. The stator core is formed as a near-net-shape compact by an electromagnetic pressing process and has an as-formed density of at least about 98% of the theoretical density.

Abstract: A reluctance rotor and method for manufacturing reluctance rotors having soft magnetic regions and regions with magnetic properties that are dissimilar to those of the soft magnetic region so as to create a flux barrier. The method generally entails producing a magnetic body having a central axis and an outer peripheral surface. The body is composed of concentric regions, at least one of which is a soft magnetic region while at least a second region of the concentric regions is formed of a material with dissimilar magnetic properties to the soft magnetic region. Once formed, the body is divided along radials thereof to form wedge-shaped members, with each wedge-shaped member having coaxial arcuate regions that are portions of the concentric regions of the body.

Abstract: A high-density stator core for use in electrodynamic devices is fabricated by the electromagnetic pressing of an iron-based powder coated with a dielectric material and methods for performing the electromagnetic pressing are disclosed. The stator core includes a yoke portion that may further include a plurality of integral poles extending either radially outward from an outer circumferential surface of the yoke portion or radially inward from an interior circumferential surface of the yoke portion. The stator core is formed as a near-net-shape compact by an electromagnetic pressing process and has an as-formed density of at least about 98% of the theoretical density.

Abstract: Ceramic-coated powdered ferromagnetic materials for forming magnetic articles, and which maintain the mechanical and magnetic properties of the articles at high temperatures, such as during annealing to relieve stresses induced during the forming operation. The ceramic coatings are formed by one of several techniques to provide an encapsulating layer on each ferromagnetic particle. The particles are then compacted to form a solid magnetic article, which can be annealed without concern for degrading the ceramic coating.

Abstract: An ignition coil for a spark ignition engine includes a cylindrical magnetic core having opposite first and second ends. Preferably, the magnetic core has a circular cross section. Permanent magnets similarly shaped as the core are disposed at the ends of the magnetic core. The magnets are made from a microencapsulated magnetic material, resulting in increased resisitivity and decreased eddy current loss. By using the microencapsulated magnets, the voltage output of the ignition coil is increased while requiring no additional input energy. A primary winding is wound about the magnetic core between the first and second ends. A secondary winding assembly is disposed about the primary winding and the core. The secondary winding assembly includes a spool and secondary winding wound thereon. The secondary winding is inductively coupled to the primary winding. An outer case is disposed about said magnetic core, magnets and the primary and secondary windings.

Abstract: Disclosed is a process for producing an AC cylindrical electromagnetic ignition coil core (28) comprising:filling a cylindrical holding container (20) with powdered metal;placing the filled container into an electromagnetic field and compacting, in the radial direction, the powder in the container by subjecting the powder to the electromagnetic field; andrecovering the compacted ignition coil core (28).