Fixtures and Methods for Forming Aligned Magnetic Cores

Abstract

Magnetic cores and method and fixtures for forming the same are disclosed. The magnetic core may comprise a magnetic body including magnetic grains and a magnetic flux path, the magnetic grains aligned in a plurality of distinct directional alignments to conform to the magnetic flux path. The grain orientation of the cores may be provided by fixtures including electrical circuits and/or permanent magnets. The fixtures may be configured to produce magnetic fields that approximate, mimic, or correspond to a magnetic flux path in the magnetic core, once it is consolidated and in use. The magnetic fields may orient the grains of the magnetic core when they are in an unconsolidated state, such that the grains are aligned in a plurality of directional alignments that approximate, mimic, or correspond to a magnetic flux path in the magnetic core.

What is claimed is: 
     
         1 . A magnetic core comprising:
 a magnetic body including magnetic grains and a magnetic flux path, the magnetic grains aligned in a plurality of distinct directional alignments to conform to the magnetic flux path.   
     
     
         2 . The magnetic core of  claim 1 , wherein each alignment is a major alignment with respect to the magnetic body. 
     
     
         3 . The magnetic core of  claim 1 , wherein the magnetic body has an inner cavity. 
     
     
         4 . The magnetic core of  claim 3 , wherein the plurality of directional alignments extend around a perimeter of the inner cavity. 
     
     
         5 . The magnetic core of  claim 4 , wherein the magnetic core is an inductor core. 
     
     
         6 . The magnetic core of  claim 1 , wherein the magnetic core is a stator core including a plurality of stator teeth and a plurality of stator slots between the stator teeth. 
     
     
         7 . The magnetic core of  claim 6 , wherein the plurality of directional alignments include a plurality of arc-shaped alignments from one stator tooth to another stator tooth around a stator slot. 
     
     
         8 . The magnetic core of  claim 1 , wherein the magnetic core is a rotor core including a plurality of permanent magnets disposed therein. 
     
     
         9 . The magnetic core of  claim 8 , wherein the plurality of directional alignments include a plurality of alignments extending between the permanent magnets and an outer perimeter of the rotor core. 
     
     
         10 . A fixture for aligning grains in a magnetic core, comprising:
 one or more inner magnets configured to be located in an interior of the core;   the inner magnets configured to generate a magnetic field in the magnetic core and align the grains in a plurality of directional alignments.   
     
     
         11 . The fixture of  claim 10 , wherein the inner magnets are configured to generate a magnetic field in the magnetic core that mimics a magnetic flux path of the magnetic core. 
     
     
         12 . The fixture of  claim 10 , wherein each inner magnet has a north (N) side and a south (S) side. 
     
     
         13 . The fixture of  claim 12 , wherein there are a plurality of inner magnets and a plurality of outer magnets configured to be located exterior to the core and each inner magnet forms a magnet pair with an outer magnet. 
     
     
         14 . The fixture of  claim 13 , wherein each magnet pair has either the N sides facing each other or the S sides facing each other and adjacent magnet pairs have opposite N and S side configurations. 
     
     
         15 . The fixture of  claim 10 , wherein the magnetic core is a stator core having a plurality of stator teeth and a plurality of stator slots between the stator teeth, the inner magnets being configured to generate a magnetic field in the stator core and align the grains in a plurality of arc-shaped alignments from one stator tooth to another stator tooth around a stator slot. 
     
     
         16 . The fixture of  claim 15 , wherein the inner magnets are configured to be located at tips of the stator teeth or in the stator slots. 
     
     
         17 . The fixture of  claim 10 , wherein the magnetic core is a rotor core and the inner magnets are rotor permanent magnets that remain in the rotor core after consolidation. 
     
     
         18 . A fixture for aligning grains in a magnetic core comprising:
 one or more inner wires configured to be located in an interior of the core and to carry electric current in a first direction; and   one or more outer wires configured to be located exterior to the core and to carry electric current in a second direction, opposite the first;   the inner and outer wires configured to generate a magnetic field in the magnetic core.   
     
     
         19 . The fixture of  claim 18 , wherein the inner and outer wires are configured to generate a magnetic field in the magnetic core and align the grains in a plurality of directional alignments that mimic a magnetic flux path of the magnetic core. 
     
     
         20 . The fixture of  claim 18 , wherein there are a plurality of inner wires and a plurality of outer wires and each inner wire forms a wire pair with an outer wire.