Flake magnetic core and method of making same

Claim 1

MAGNETIC FLAKE CORE MANUFACTURING PROCESS COMPRISING ANNEALING POWDERED MAGNETIC METALLIC MATERIAL INCLUDING MOLYBDENUM, NICKEL AND IRON NEAR 800*C. AND HIGHER FOR FIVE TO TEN HOURS, LUBRICATING ROLL SURFACES TO BE USED IN ROLLING MATERIAL, ROLLING POWDERED MATERIAL BETWEEN LUBRICATED ROLL SURFACES TO FORM FLAKE MATERIAL HAVING AN AVERAGE THICKNESS OF 20 TO 24 MICRONS AND AN AVERAGE DIAMETER NEAR 300 MICRONS, DEGREASING THE FLAKE MATERIAL TO REMOVE SUBSTANTIALLY ALL LUBRICANT FROM THE ROLLED FLAKE MATERIAL, BLENDING PULVERIZED MICA WITH DEGREASED FLAKE MATERIAL TO INHIBIT AGGLOMERATION, ANNEALING THE MICA BLENDED FLAKE MATERIAL NEAR 800*C. AND HIGHER FOR FIVE TO TEN HOURS IN HYDROGEN-CONTAINING ATMOSPHERE, APPLYING A PLURALITY OF INDIVIDUAL ELECTRICAL INSULATION COATINGS TO ANNEALED FLAKE MATERIAL WITH INTERMEDIATE DRYING OF EACH COATING, AT LEAST ONE SUCH COATING INCLUDING MICA, FEEDING INSULATED FLAKE MATERIAL INTO A CIRCUMFERENTIALLY-CONTINUOUS TOROIDAL-CONFIGURATION DIE SUCH THAT FLAKES ARE ARRANGED IN THE DIE IN SUBSTANTIALLY PARALLEL RELATIONSHIP, ADDING POWDERED MAGNETIC METAL MATERIAL ON TOP OF THE FLAKE MATERIAL IN THE DIE, PRESSURE FORMING FLAKE AND POWDERED MATERIAL IN THE DIE TO FORM A FLAKE CORE, ANNEALING THE CORE IN HYDROGEN NEAR 800*C. TO 1000*C. FOR 15 TO 30 MINUTES, COOLING THE ANNEALED CORE AT A RATE NEAR 25*C. PER MINUTE IN A NON-OXIDIZING ATMOSPHERE, ROUNDING OFF POWDERED MATERIAL EDGES OF THE CORE, COATING OUTER SURFACES OF THE CORE TO MINIMIZE MOISTURE PENETRATION OF THE CORE.