Abstract: A system for use in leaching a plurality of polycrystalline diamond cutter elements includes a plurality of leaching receptacles having a first and a second cavity, the second cavity being arranged to receive a volume of liquid acid leaching mixture. A plurality of removable fixtures, each being adapted to hold an individual cutter element to be leached, are provided and the first cavity of each leaching receptacle is adapted to receive a respective one of said fixtures. A plurality of seal members are positionable in a recess in a respective one of said fixtures and arranged to extend around the respective cutter element. The leaching receptacle are adapted to interconnect with a respective one of said fixtures holding a respective cutter element to form a closed system, with the cutter element in the respective fixture forming a lid to seal the respective leaching receptacle with the respective fixture.

Abstract: A method for leaching a plurality of polycrystalline diamond (PCD) cutter elements is disclosed as providing a leaching receptacle for each PCD cutter element, introducing a volume of liquid acid leaching mixture into each leaching receptacle, attaching each PCD cutter element to a respective fixture, applying a seal member around each PCD cutter element, suspending the PCD cutter elements above the acid leaching mixtures in the respective leaching receptacles, sealing each leaching receptacle to provide a plurality of closed systems, elevating the temperature of the liquid acid leaching mixture in each leaching receptacle to above ambient conditions to transition at least some of the liquid acid leaching mixture to acid vapour(s) and exposing the PCD cutter elements to the acid vapour(s) to leach the PCD cutter elements.

Abstract: A method for leaching a polycrystalline diamond (PCD) cutter element includes providing a leaching receptacle, introducing a volume of liquid acid leaching mixture into the leach ing receptacle, attaching the PCD cutter element to a fixture, applying a seal member around the PCD cutter element, locating the fixture with the PCD cutter element attached in the leaching receptacle to suspend the PCD cutter element above the acid leaching mixture, sealing the leaching receptacle to provide a closed system, elevating the temperature of the liquid acid leaching mixture to above ambient conditions to transition at least some of the liquid acid leaching mixture to acid vapour(s) and exposing the PCD cutter element to the acid vapour(s) to leach the PCD cutter element.

Abstract: A method for leaching a polycrystalline diamond cutter element is disclosed as providing a leaching receptacle having a first cavity and a second cavity therein. A volume of liquid acid leaching mixture is introduced into the second cavity. The PCD cutter element is attached to a fixture and a seal member is positioned around a portion of the PCD cutter element and located in a recess in the fixture. The PCD cutter element is located in the second cavity. The fixture is connected to the leaching receptacle, compressing the seal member against and/or between the cutter and the leaching receptacle to form a closed system with the PCD cutter to be leached in the fixture forming a lid. The temperature of the liquid acid leaching mixture is elevated to above ambient conditions to leach at least a portion of the PCD cutter element.

Abstract: An apparatus for use in leaching a polycrystalline diamond (PCD) cutter element is disclosed and includes a leaching receptacle having a first cavity and a second cavity, the first cavity extending from a first end of the leaching receptacle to a first open end of the second cavity, the second cavity extending from the first open end to a second end and being arranged to receive a volume of liquid acid leaching mixture. A removable fixture is adapted to hold the PCD cutter element to be leached. A seal member is positionable adjacent the first open end of the second cavity and arranged to extend around the PCD cutter element. The leaching receptacle and the fixture holding the PCD cutter are adapted to interconnect to form a closed system with the PCD cutter to be leached in the fixture forming a lid to close and seal the apparatus.

Abstract: We describe a method of manufacturing a stator of an axial flux permanent magnet machine, the machine having a stator comprising a stator housing defining a chamber comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: providing first and second radial walls for said stator housing; providing inner and outer side walls for said stator housing; assembling said first and second radial walls and said inner and outer side walls around said set of coils to form a stator assembly, wherein said assembling further comprises: providing one or more collapsible elements between said side walls and one or both of said first and second radial walls; and attaching said

Abstract: We describe a method of manufacturing a stator of an axial flux permanent magnet machine, the machine having a stator comprising a stator housing defining a chamber comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: providing first and second radial walls for said stator housing; providing inner and outer side walls for said stator housing; assembling said first and second radial walls and said inner and outer side walls around said set of coils to form a stator assembly, wherein said assembling further comprises: providing one or more collapsible elements between said side walls and one or both of said first and second radial walls; and attaching said

Abstract: We describe a method of manufacturing a housing for the stator of an axial flux permanent magnet machine, the machine having a stator comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: fabricating a radial wall for said stator housing to be located in said gap between said rotor and said stator by: placing a resin membrane into a mold of an injection molding machine; injection molding a set of reinforcing features onto said membrane using a thermoplastic polymer bondable when molten with said resin; and manufacturing said housing using said radial wall.

Abstract: We describe a method of manufacturing a housing for the stator of an axial flux permanent magnet machine, in particular a Yokeless and Segmented Armature motor, the machine having a stator comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction.

Abstract: We describe a method of manufacturing a stator of an axial flux permanent magnet machine, the machine having a stator comprising a stator housing defining a chamber comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: providing first and second radial walls for said stator housing; providing inner and outer side walls for said stator housing; assembling said first and second radial walls and said inner and outer side walls around said set of coils to form a stator assembly, wherein said assembling further comprises: providing one or more collapsible elements between said side walls and one or both of said first and second radial walls; and attaching said

Abstract: We describe a method of manufacturing a housing for the stator of an axial flux permanent magnet machine, the machine having a stator comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: fabricating a radial wall for said stator housing to be located in said gap between said rotor and said stator by: placing a resin membrane into a mould of an injection moulding machine; injection moulding a set of reinforcing features onto said membrane using a thermoplastic polymer bondable when molten with said resin; and manufacturing said housing using said radial wall.

Abstract: We describe a method of manufacturing a housing for the stator of an axial flux permanent magnet machine, in particular a Yokeless and Segmented Armature motor, the machine having a stator comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction.