Abstract: This invention relates to a system and method for loading a plurality of powder materials into a magnetic compaction tool. The system and method employ a powder loader which guides the plurality of powder materials into predetermined locations in the magnetic compaction tool so that when the tool is electromagnetically energized, the plurality of powder materials are compacted to form a part having a plurality of densified metals formed by the plurality of powder materials.

Abstract: This invention relates to a transformer and more particularly, to a system and method for making a transformer utilizing dynamic magnetic compaction. A coil is placed in a conductive container, and a conductive powder material, such as ferrite, is placed in the container and surrounds the coil and the turns of the coil. A power supply energizes a capacitor which subsequently provides a high energizing current to a second, energizing coil within which the container, material and inner coil are situated, thereby causing the container, powder materials and coil to be compacted to provide an electrical component, such as a transformer, motor, commutator, rotor or choke.

Abstract: Process for die extrusion of melted polymers that reduces die lip buildup and its deleterious effects. Direct extrusion of mixed polymer pellets and filler concentrate pellets in one embodiment avoids a precompounding step and reduces the tendency of polymer and filler particles to adhere to the exit portion of the die. In other embodiments a reduced die lip radius and lower melt processing temperatures further enhance the benefits obtained. For co-extruded muitilayer film embodiments elimination of fillers and antiblock additives in skin layers add to the levels of die lip buildup reduction obtained. Hours of continuous operation without excessive die lip buildup in one arrangement have been increased from a level of 4 to 6 hours, for example, to in excess of 20 hours. Reduced product defect levels have also been attained.