Abstract: A motor comprises a stator comprising at least one core; a coil wound on the at least one core of the stator; a rotor having a rotor pole and being rotatably mounted relative to the stator; and at least one magnet disposed between the rotor and the stator. The at least one core comprises a composite material defined by iron-containing particles having an alumina layer disposed thereon.

Abstract: A bulk material formed on a surface is provided. The bulk material includes a plurality of adhered domains of metal material, substantially all of the domains of the plurality of domains of metal material separated by a predetermined layer of high resistivity insulating material. A first portion of the plurality of domains forms a surface. A second portion of the plurality of domains includes successive domains of metal material progressing from the first portion. Substantially all of the domains in the successive domains each include a first surface and a second surface, the first surface opposing the second surface, the second surface conforming to a shape of progressed domains, and a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.

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.

Abstract: Manufacturing processes monitor forces or pressures within a machine. Metal within machines affect wireless communications within the machines for reporting monitored data. An embodiment of the present invention is a sensor that provides wireless communications unaffected by metals and with less electrical noise than slip rings. An embodiment can monitor manufacturing processes, such as by employing a piezoelectric transducer to measure forces or pressures in a machine and generate an electrical signal representing, for example, forces measured by the piezoelectric transducer. A threshold modulator circuit converts the electrical signal into a series of electrical pulses, which can be transmitted as a corresponding series of magnetic field pulses to a wireless receiver. The receiver reconstructs the original electrical signal, thereby enabling a receiver system to determine physical activities in the machine. The embodiment may be self-powered through use of power generated by the piezoelectric transducer.

Abstract: A hybrid field electric motor includes a rotor with a rotor core rotating about an axial axis and having a rotor surface with at least one sloping edge face and a radial edge face. The stator includes a stator core and radial pole faces spaced by a gap from the radial edge face of the rotor for radially directing flux into the rotor core. The stator has sloping pole faces spaced from the sloping edge face of the rotor core for flux directed into the rotor core at an angle between radial and axial. The rotor core and/or stator core are made of a soft magnetic composite material for flux in inure than one plane in the core(s).

Abstract: A system for forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material. The systems has a heating device; a deposition device; a support configured to support the soft magnetic bulk material of the predetermined shape; and a mask configured as a negative of at least a portion of the predetermined shape. The heating device heats the magnetic material to form particles having a softened state and wherein the deposition device deposits successive layers of particles of the magnetic material in the softened state on the support with the mask located between the deposition device and the support. The mask is indexed to a position relative to the support upon deposition of the successive layers. The mask selectively blocks the successive layers of particles of the magnetic material in the softened state from being deposited on the support forming the soft magnetic bulk material of a predetermined shape on the support.

Abstract: Manufacturing processes monitor forces or pressures within a machine. Metal within machines affect wireless communications within the machines for reporting monitored data. An embodiment of the present invention is a sensor that provides wireless communications unaffected by metals and with less electrical noise than slip rings. An embodiment can monitor manufacturing processes, such as by employing a piezoelectric transducer to measure forces or pressures in a machine and generate an electrical signal representing, for example, forces measured by the piezoelectric transducer. A threshold modulator circuit converts the electrical signal into a series of electrical pulses, which can be transmitted as a corresponding series of magnetic field pulses to a wireless receiver. The receiver reconstructs the original electrical signal, thereby enabling a receiver system to determine physical activities in the machine. The embodiment may be self-powered through use of power generated by the piezoelectric transducer.

Abstract: A bulk material formed on a surface is provided. The bulk material includes a plurality of adhered domains of metal material, substantially all of the domains of the plurality of domains of metal material separated by a predetermined layer of high resistivity insulating material. A first portion of the plurality of domains forms a surface. A second portion of the plurality of domains includes successive domains of metal material progressing from the first portion. Substantially all of the domains in the successive domains each include a first surface and a second surface, the first surface opposing the second surface, the second surface conforming to a shape of progressed domains, and a majority of the domains in the successive domains in the second portion having the first surface comprising a substantially convex surface and the second surface comprising one or more substantially concave surfaces.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface, a gas subsystem configured to introduce one or more reactive gases to an area proximate in-flight droplets. The one or more reactive gases creates an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a combustion chamber, a gas inlet configured to inject a gas into the combustion chamber, a fuel inlet configured to inject a fuel into the combustion chamber, an igniter subsystem configured to ignite a mixture of the gas and the fuel to create a predetermined temperature and pressure in the combustion chamber, a metal powder inlet configured to inject a metal powder comprised of particles coated with an electrically insulating material into the combustion, wherein the predetermined temperature creates conditioned droplets comprised of the metal powder in the chamber, and an outlet configured to eject and accelerate combustion gases and the conditioned droplets from the combustion chamber and towards a surface such that conditioned droplets adhere to the surface to form a material having domains with insulated boundaries thereon.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface, a spray subsystem configured to direct a spray of an agent at deposited droplets on the surface. The agent creates insulation layers on the deposited droplets such that the droplets form a material having domains with insulated boundaries on the surface.