Sintered ferromagnetic powder metal parts for alternating current applications

Claim 3

The method as set forth in claim 1 wherein the individual cross sections are separated by an air gap.

Claim 4

The method as set forth in claim 1 wherein the individual cross sections are separated by a magnetic insulating medium.

Claim 5

The method as set forth in claim 3 wherein the magnetic insulating medium is selected from the group consisting of aluminum oxide, zirconium oxide and insulating paper.

Claim 6

The method as set forth in claim 1 wherein the core exhibits a 60 Hertz core loss of less than 2.0 watts per pound when subjected to an alternating current magnetizing force at an induction level of 7 kilogauss.

Claim 7

The method as set forth in claim 1 wherein the individual cross sections are sintered prior to stacking.

Claim 9

The method as set forth in claim 1 wherein the thickness of the individual cross sections is at least 0.008 inch.

Claim 10

The method as set forth in claim 8 wherein the thickness of the individual cross sections is less than 0.150 inch.

Claim 11

A ferromagnetic powder metal core for alternating current applications said core consisting of a plurality of core cross sections, each cross section having a fixed cross sectional dimension, with the sections arranged such that the faces of adjacent parts are stacked in vertical alignment in noncontacting relationship, said core produced by pressing a ferromagnetic powder into a cross section of the core, with the thickness of the cross section approaching that below which the green density is no longer uniform throughout the volume of the part, pressing sufficient magnetic powder metal cross sections to meet the overall core thickness requirement when the cross sections are subsequently stacked in vertical alignment with all individual cross sections of substantially equal thickness of at least 0.008 inch, assembling the individual cross sections in vertical alignment with the cross sectional faces of adjacent parts in noncontacting relationship, and sintering the cross sections.

Claim 12

A ferromagnetic powder metal core for alternating current applications said core consisting of a plurality of core cross sections, each cross section having a fixed cross sectional dimension, with the sections arranged such that the faces of adjacent parts are stacked in vertical alignment in noncontacting relationship, said core produced by pressing a ferromagnetic powder into a cross section of the core, with the thickness of the cross section approaching that below which the green density is no longer uniform throughout the volume of the part, pressing sufficient magnetic powder metal cross sections to meet the overall core thickness requirement when the cross sections are subsequently stacked in vertical alignment with all individual cross sections of substantially equal thickness of at least 0.008 inch, assembling the individual cross sections in vertical alignment with the cross sectional faces of adjacent parts in noncontacting relationship, and sintering the cross sections.