Bonded amorphous metal electromagnetic components

Claim 1

A method for preparing a laminate composite for a magnetic core useful in a transformer or stator comprising the steps of assembling a plurality of thin polymer-coated metal ribbons of a magnetic metal in an applied magnetic field, said magnetic metal being at least 50 percent amorphous and having the composition represented by the formula, A.sub.x Z.sub.y, wherein A is one or more of Fe, Co, Ni, Mo, W, Cr, and V, Z is one or more of Si, C, B, P, Al, Sn, Sb, Ge, In, and Be, x is an atomic percentage of from 70-90, and y is an atomic percentage of from 30-10, said polymer-coated ribbons being disposed in a plurality of layers, each of said layers being composed of a plurality of said polymer-coated ribbons arranged with at least one edge of each polymer-coated ribbon contiguous with an edge of another polymer-coated ribbon and said layers being disposed relative to each other so that abutting edges in contiguous layers are covered by solid magnetic metal, simultaneously subjecting the polymer-coated ribbons so assembled to pressurization in excess of about 1000 psi and to heating to a temperature in excess of the annealing temperature and below the recrystallization temperature of said magnetic metal, and converting the annealed assembly of ribbons as required to convert said assembly into a shaped laminate suitable for construction of said magnetic core.

Claim 2

A method for preparing a laminate composite for a magnetic core useful in a transformer or stator comprising the steps of assembling a plurality of thin polymer-coated metal ribbons of a magnetic metal in an applied magnetic field, said magnetic metal being at least 50 percent amorphous and having the composition represented by the formula, A.sub.x Z.sub.y, wherein A is one or more of Fe, Co, Ni, Mo, W, Cr, and V, Z is one or more of Si, C, B, P, Al, Sn, Sb, Ge, In, and Be, x is an atomic percentage of from 70-90, and y is an atomic percentage of from 30-10, said polymer-coated ribbons being disposed in a plurality of layers, each of said layers being composed of a plurality of said polymer-coated ribbons arranged with at least one edge of each polymer-coated ribbon contiguous with an edge of another polymer-coated ribbon and said layers being disposed relative to each other so that abutting edges in contiguous layers are covered by solid magnetic metal, simultaneously subjecting the polymer-coated ribbons so assembled to pressurization in excess of about 1000 psi and to heating to a temperature in excess of the annealing temperature and below the recrystallization temperature of said magnetic metal, and converting the annealed assembly of ribbons as required to convert said assembly into a shaped laminate suitable for construction of said magnetic core.