Abstract: A bulk amorphous metal magnetic component has a plurality of laminations of ferromagnetic amorphous metal strips adhered together to form a generally three-dimensional part having the shape of a polyhedron. The component is formed by stamping, stacking and bonding. The bulk amorphous metal magnetic component may include an arcuate surface, and an implementation may include two arcuate surfaces that are disposed opposite each other. The magnetic component may be operable at frequencies ranging from between approximately 50 Hz and 20,000 Hz. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it may exhibit a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3+0.000282 f1.5 (Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal inductive device includes a magnetic core having at least one low-loss bulk ferromagnetic amorphous metal magnetic component forming a magnetic circuit having an air therein. The component has a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhedrally shaped part. The device has one or more electrical windings and is easily customized for specialized magnetic applications, e.g. for use as a transformer or inductor in power conditioning electronic circuitry employing switch-mode circuit topologies and switching frequencies ranging from 1 kHz to 200 kHz or more. The low core losses of the device, e.g. a loss of at most about 12 W/kg when excited at a frequency of 5 kHz to a peak induction level of 0.3 T, make it especially useful at frequencies of 1 kHz or more.

Abstract: A selective etching process cuts shapes from amorphous metal strip feedstock. The etching process comprises depositing a chemically resistant material to one side of the strip in a pattern that defines the requisite shape, mating the metal strip with a carrier strip, exposing at least one side of the metal strip to an etching agent to selectively etch the desired shape, and separating the shape from the strip feedstock. A plurality of layers of the shapes is assembled by adhesive lamination to form a generally polyhedrally shaped bulk amorphous metal magnetic component useful in high efficiency electric motors and inductive devices. The bulk amorphous metal magnetic component may include an arcuate surface, and preferably includes two arcuate surfaces that are disposed opposite to each other. The magnetic component is operable at frequencies ranging from about 50 Hz to about 20,000 Hz.

Abstract: A unitary amorphous metal magnetic component for an axial flux electric machine such as a motor or generator is formed from a spirally wound annular cylinder of ferromagnetic amorphous metal strips. The cylinder is adhesively bonded and provided with a plurality of slots formed in one of the annular faces of the cylinder and extending from the inner diameter to the outer diameter of the cylinder. The component is preferably employed in constructing a high efficiency, axial flux electric motor. When operated at an excitation frequency “f” to a peak induction level Bmax the unitary amorphous metal magnetic component has a core-loss less than “L” wherein L is given by the formula L=0.0074f(Bmax)1.3+0.000282f1.5(Bmax)2.4, the core loss, excitation frequency and peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal magnetic component has a plurality of laminations of ferromagnetic amorphous metal strips adhered together to form a generally three-dimensional part having the shape of a polyhedron. The component is formed by stamping, stacking and bonding. The bulk amorphous metal magnetic component may include an arcuate surface, and an implementation may include two arcuate surfaces that are disposed opposite each other. The magnetic component may be operable at frequencies ranging from between approximately 50 Hz and 20,000 Hz. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it may exhibit a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3+0.000282 f1.5 (Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal inductive device comprises a magnetic core having at least one low-loss bulk ferromagnetic amorphous metal magnetic component forming a magnetic circuit having an air gap therein. The component comprises a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhederally shaped part. The device has one or more electrical windings and is easily customized for specialized magnetic applications, e.g. for use as a transformer or inductor in power conditioning electronic circuitry employing switch-mode circuit topologies and switching frequencies ranging from 1 kHz to 200 kHz or more. The low core losses of the device, e.g. a loss of at most about 12 W/kg when excited at a frequency of 5 kHz to a peak induction level of 0.3 T, make it especially useful at frequencies of 1 kHz or more.

Abstract: A selective etching process cuts shapes from amorphous metal strip feedstock. The etching process comprises depositing a chemically resistant material to one side of the strip in a pattern that defines the requisite shape, mating the metal strip with a carrier strip, exposing at least one side of the metal strip to an etching agent to selectively etch the desired shape, and separating the shape from the strip feedstock. A plurality of layers of the shapes is assembled by adhesive lamination to form a generally polyhedrally shaped bulk amorphous metal magnetic component useful in high efficiency electric motors and inductive devices. The bulk amorphous metal magnetic component may include an arcuate surface, and preferably includes two arcuate surfaces that are disposed opposite to each other. The magnetic component is operable at frequencies ranging from about 50 Hz to about 20,000 Hz.

Abstract: A unitary amorphous metal magnetic component for an axial flux electric machine such as a motor or generator is formed from a spirally wound annular cylinder of ferromagnetic amorphous metal strips. The cylinder is adhesively bonded and provided with a plurality of slots formed in one of the annular faces of the cylinder and extending from the inner diameter to the outer diameter of the cylinder. The component is preferably employed in constructing a high efficiency, axial flux electric motor. When operated at an excitation frequency “f” to a peak induction level Bmax the unitary amorphous metal magnetic component has a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3+0.000282 f1.5 (Bmax)2.4, the core loss, excitation frequency and peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A high efficiency electric motor has a generally polyhedrally shaped bulk amorphous metal magnetic component in which a plurality of layers of amorphous metal strips are laminated together adhesively to form a generally three-dimensional part having the shape of a polyhedron. The bulk amorphous metal magnetic component may include an arcuate surface, and preferably includes two arcuate surfaces that are disposed opposite to each other. The magnetic component is operable at frequencies ranging from about 50 Hz to about 20,000 Hz. When the motor is operated at an excitation frequency “f” to a peak induction level Bmax, the component exhibits a core-loss less than about “L” wherein L is given by the formula L=0.005 f (Bmax)1.5+0.000012 f1.5 (Bmax)1.6, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A high efficiency electric motor has a generally polyhedrally shaped bulk amorphous metal magnetic component in which a plurality of layers of amorphous metal strips are laminated together adhesively to form a generally three-dimensional part having the shape of a polyhedron. The bulk amorphous metal magnetic component may include an arcuate surface, and preferably includes two arcuate surfaces that are disposed opposite to each other. The magnetic component is operable at frequencies ranging from about 50 Hz to about 20,000 Hz. When the motor is operated at an excitation frequency “f” to a peak induction level Bmax, the component exhibits a core-loss less than about “L” wherein L is given by the formula L=0.005 f(Bmax)1.5+0.000012 f1.5(Bmax)1.6, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal magnetic component for an electric machine such as a motor or generator is described. The component may include a plurality of substantially similarly shaped laminations stamped from ferromagnetic amorphous metal strips, stacked and bonded together in registry, wherein the laminations include a plurality of tooth-shaped sections. In an alternate implementation, the component may be constructed by first stacking a plurality of layers of amorphous metal strips, laminating the layers and then cutting the object to form the component. The bulk amorphous metal magnetic component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0074 f(Bmax)1.3+0.000282 f1.5(Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal inductive device comprises a magnetic core having at least low-loss bulk ferromagnetic amorphous metal magnetic component forming a magnetic circuit having an air gap therein. The device has one or more electrical windings and may be used as a transformer or inductor in an electronic circuit. The component comprises a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhedrally shaped part. The low core losses of the device, e.g. a loss of at most about 12 W/kg when excited at a frequency of 5 kHz to a peak induction level of 0.3 T, make it especially useful for application in power conditioning circuits operating in switched mode at frequencies of 1 kHz or more. The component is fabricated by a process comprising cutting laminations of the requisite shape. The cut laminations are stacked and registered, and then bonded by an adhesive agent. The cutting of laminations is advantageously done with stamping or photolithographic etching techniques.

Abstract: A unitary amorphous metal magnetic component for an axial flux electric machine such as a motor or generator is formed from a spirally wound annular cylinder of ferromagnetic amorphous metal strips. The cylinder is adhesively bonded and provided with a plurality of slots formed in one of the annular faces of the cylinder and extending from the inner diameter to the outer diameter of the cylinder. The component is preferably employed in constructing a high efficiency, axial flux electric motor. When operated at an excitation frequency “f” to a peak induction level Bmax the unitary amorphous metal magnetic component has a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3+0.000282 f1.5 (Bmax)2.4, the core loss, excitation frequency and peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A unitary amorphous metal magnetic component for an axial flux electric machine such as a motor or generator is formed from a spirally wound annular cylinder of ferromagnetic amorphous metal strips. The cylinder is adhesively bonded and provided with a plurality of slots formed in one of the annular faces of the cylinder and extending from the inner diameter to the outer diameter of the cylinder. The component is preferably employed in constructing a high efficiency, axial flux electric motor. When operated at an excitation frequency “f” to a peak induction level Bmax the unitary amorphous metal magnetic component has a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3+0.000282 f1.5 (Bmax)2.4, the core loss, excitation frequency and peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal magnetic component has a plurality of laminations of ferromagnetic amorphous metal strips adhered together to form a generally three-dimensional part having the shape of a polyhedron. The component is formed by stamping, stacking and bonding. The bulk amorphous metal magnetic component may include an arcuate surface, and an implementation may include two arcuate surfaces that are disposed opposite each other. The magnetic component may be operable at frequencies ranging from between approximately 50 Hz and 20,000 Hz. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it may exhibit a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3+0.000282 f1.5 (Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal magnetic component has a plurality of laminations of ferromagnetic amorphous metal strips adhered together to form a generally three-dimensional part having the shape of a polyhedron. The component is formed by stamping, stacking and bonding. The bulk amorphous metal magnetic component may include an arcuate surface, and an implementation may include two arcuate surfaces that are disposed opposite each other. The magnetic component may be operable at frequencies ranging from between approximately 50 Hz and 20,000 Hz. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it may exhibit a core-loss less than “L” wherein L is given by the formula L=0.0074 f(Bmax)1.3+0.000282 f1.5(Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal magnetic component for an electric machine such as a motor or generator is described. The component may include a plurality of substantially similarly shaped laminations stamped from ferromagnetic amorphous metal strips, stacked and bonded together in registry, wherein the laminations include a plurality of tooth-shaped sections. In an alternate implementation, the component may be constructed by first stacking a plurality of layers of amorphous metal strips, laminating the layers and then cutting the object to form the component. The bulk amorphous metal magnetic component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3+0.000282 f1.5 (Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A bulk amorphous metal magnetic component has a plurality of laminations of ferromagnetic amorphous metal strips adhered together to form a generally three-dimensional part having the shape of a polyhedron. The component is formed by stamping, stacking and bonding. The bulk amorphous metal magnetic component may include an arcuate surface, and an implementation may include two arcuate surfaces that are disposed opposite each other. The magnetic component may be operable at frequencies ranging from between approximately 50 Hz and 20,000 Hz. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it may exhibit a core-loss less than “L” wherein L is given by the formula L=0.0074 f (Bmax)1.3 +0.000282 f1.5 (Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.