Hybrid stator core component design for axial flux motors

Abstract

The present disclosure relates to a hybrid stator core component design for an axial flux motor. A hybrid stator core component for an axial flux motor stator and a method for manufacturing the same are provided. The hybrid stator core component includes a molded soft magnetic composite material and a laminate component. In one embodiment, a laminate insert including multiple insulating layers is non-releasably located within the molded soft magnetic composite material. In another embodiment, the hybrid stator core component has a molded soft magnetic composite core and a laminate shell disposed around at least a portion of the molded soft magnetic composite core, the laminate shell including multiple layers.

Description

Technical Field

[0001] This section provides background information related to the present disclosure which is not necessarily prior art.

[0002] The present disclosure relates generally to a hybrid stator core component for a stator of an axial flux motor, and more particularly, to a hybrid stator core component having a molded soft magnetic core component and a laminate component including a plurality of insulating layers of magnetic material. Background Art

[0003] Electric motors convert electrical energy into mechanical work by generating torque, while generators convert mechanical work into electrical energy. Electric vehicles, including hybrid vehicles, employ electric motors / generators, such as induction motors and permanent magnet motors, to propel the vehicle, as well as to capture braking energy when acting as generators. Motors will be mentioned in this article; however, it should be understood that these principles also apply to generators. Typically, an electric motor includes a rotor that rotates during operation and a stationary stator. The rotor may contain multiple permanent magnets and rotate relative to a fixed stator. The rotor is connected to a rotor shaft, which also rotates with the rotor. The rotor, including permanent magnets, is separated from the stator by a predetermined air gap. The stator includes a conductor in the form of a wire winding. When electrical energy is applied through the wire winding, a magnetic field is generated. When electrical energy is fed into the conductive windings of the stator, torque is generated by the magnetic flux acting on the permanent magnets in the rotor, and power can be transmitted across the air gap. In this way, mechanical power can be transmitted to the rotating rotor shaft. Therefore, in an electric vehicle, the rotor transmits torque to the drive wheels of the vehicle via a rotating shaft through a gear set.

[0004] Two common types of electric motors include radial flux and axial flux motors. In a radial flux motor, the rotor and stator are typically positioned in a concentric or nested configuration so that when the stator is energized, it produces a magnetic flux that extends radially from the stator to the rotor. Therefore, the conductive windings in the stator are typically arranged parallel to the axis of rotation, thereby producing a magnetic field that is oriented in a radial direction from the axis of rotation (along the rotor axis). In an axial flux motor, a magnetic field parallel to the axis of rotation is produced by conductive wire windings in the stator, so that the magnetic flux extends parallel to the axis of rotation (parallel to the rotor axis). In certain applications, axial flux motors are desirable because they are relatively light, produce more power, and have a compact size compared to radial flux motors. Summary of the invention

[0005] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0006] The present disclosure relates to a hybrid stator core component for an axial flux motor stator, the hybrid stator core component comprising a laminate insert having a plurality of insulating layers, the insulating layers comprising a ferromagnetic material. In addition, a molded soft magnetic composite material is disposed around a portion of an outer periphery of the laminate insert. The laminate insert is non-releasably located within the molded soft magnetic composite material.

[0007] In one aspect, the molded soft magnetic composite material defines an outer surface including at least one recessed region configured to receive a wire winding.

[0008] In one aspect, each layer in the plurality of layers has substantially the same size.

[0009] In one aspect, the laminate insert has a rectangular cross-sectional shape.

[0010] In one aspect, the laminate insert defines a first region of a first outer surface of the hybrid stator core segment and a second region of a second outer surface of the hybrid stator core segment.

[0011] In one aspect, the hybrid stator core segment further includes a plurality of laminate inserts defining an insert assembly. The molded soft magnetic composite material is disposed around a portion of each of the plurality of laminate inserts in the insert assembly.

[0012] In another aspect, the insert assembly includes at least three laminate inserts.

[0013] In another aspect, the insert assembly includes at least five laminate inserts.

[0014] In one aspect, the molded soft magnetic composite defines a substantially trapezoidal outer cross-sectional shape.

[0015] In one aspect, the ferromagnetic material comprises steel. The soft magnetic composite material comprises a plurality of magnetic particles, the magnetic particles comprising iron.

[0016] In one aspect, an axial flux motor includes a stator including a plurality of hybrid stator core pieces like those described above, wherein each hybrid stator core piece has a wire disposed around its exterior. The axial flux motor also includes a rotor facing the stator and including a plurality of magnets, wherein the stator and the rotor define an air gap therebetween. A rotor shaft is coupled to the rotor and defines an axis of rotation. A plurality of insulating layers each define a main plane parallel to one another.

[0017] The present disclosure also relates to a hybrid stator core component for an axial flux motor stator, comprising a molded soft magnetic composite core and a laminate shell. The laminate shell comprises a plurality of layers including a ferromagnetic material disposed around at least a portion of the molded soft magnetic composite core.

[0018] In one aspect, an insulating material is disposed adjacent to at least one of the plurality of layers.

[0019] In one aspect, the laminate housing defines an outer surface including at least one recessed area configured to receive a wire winding.

[0020] In one aspect, the ferromagnetic material comprises steel and the soft magnetic composite material comprises a plurality of magnetic particles comprising iron.

[0021] In one aspect, an axial flux motor includes a stator including a plurality of hybrid stator core pieces like those described above, wherein each hybrid stator core piece has a wire disposed around its exterior. The axial flux motor also includes a rotor facing the stator and including a plurality of magnets, wherein the stator and the rotor define an air gap therebetween. A rotor shaft is coupled to the rotor and defines an axis of rotation.

[0022] The present disclosure also relates to a method for manufacturing a hybrid stator core component for an axial flux motor stator. The method includes placing a laminate insert in a mold, the laminate insert including a plurality of insulating layers, the insulating layers including a ferromagnetic material, the mold having a predetermined shape corresponding to the hybrid stator core component. A precursor of a soft magnetic composite material including a plurality of magnetic particles is introduced into the mold, each magnetic particle having an insulating coating. Pressure is applied to mold the soft magnetic composite material around a portion of an outer periphery of the laminate insert, wherein the laminate insert is non-releasably located within the molded soft magnetic composite material.

[0023] In one aspect, the laminate insert is a plurality of laminate inserts forming an insert assembly.

[0024] In one aspect, the method further comprises forming the laminate insert by stamping each layer from a sheet of ferromagnetic material and stacking the layers together prior to positioning in the mold.

[0025] Further areas of applicability will become apparent from the description provided herein.The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0027] Figure 1 A representative axial flux motor having one stator and two rotors is shown;

[0028] Figure 2 A laminated stator core component comprising a plurality of laminate layers is shown;

[0029] Figure 3 A molded soft magnetic composite stator core component is shown;

[0030] Figure 4 shows a plurality of Figure 3 A stator having a stator core component as described in;

[0031] Figure 5 A hybrid stator core component prepared according to certain aspects of the present disclosure is shown, having a laminate insert and a molded soft magnetic composite material;

[0032] Figure 6 Another hybrid stator core component prepared according to certain other aspects of the present disclosure is shown, having a laminate insert and a molded soft magnetic composite material;

[0033] Figure 7 A hybrid stator core component prepared according to yet another aspect of the present disclosure is shown, having an insert assembly including a plurality of laminated inserts and a molded soft magnetic composite material;

[0034] Figure 8 Another hybrid stator core component prepared according to certain other aspects of the present disclosure is shown, having an insert assembly including a plurality of laminated inserts and a molded soft magnetic composite material; and

[0035] Fig. 9 A hybrid stator core component prepared according to further aspects of the present disclosure is shown having a molded soft magnetic composite core and a laminate shell disposed around the core, the laminate shell including a plurality of layers including ferromagnetic material.

[0036] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0037] Example embodiments are provided so that the present disclosure will be thorough and will fully convey the scope to those skilled in the art. Many specific details, such as examples of specific compositions, components, devices, and methods, are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, and that the example embodiments may be implemented in many different forms, and none of this should be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail.

[0038] The terms used herein are only to describe specific example embodiments and are not intended to be limiting. Unless the context clearly indicates otherwise, as used herein, the singular forms "one", "an" and "the" may also be intended to include plural forms. The terms "include", "comprise", "contain", and "have" are inclusive, and therefore specify the existence of the stated features, elements, compositions, steps, integers, operations and / or parts, but do not exclude the existence or addition of one or more other features, integers, steps, operations, elements, parts and / or their groups. Although the open term "comprising" should be understood as a non-limiting term for describing and advocating various embodiments described herein, in some aspects, the term may be alternatively understood as a more restrictive and constraining term, such as "consisting of..." or "consisting essentially of...". Therefore, for any given embodiment of enumerating compositions, materials, parts, elements, features, integers, operations and / or process steps, the present disclosure also specifically includes embodiments consisting of or essentially consisting of these enumerated compositions, materials, parts, elements, features, integers, operations and / or process steps. In the case of “consisting of,” alternative embodiments exclude any additional compositions, materials, components, elements, features, integers, operations and / or process steps, while in the case of “consisting essentially of,” any additional compositions, materials, components, elements, features, integers, operations and / or process steps that substantially affect the basic and novel characteristics are excluded from the embodiment, but any compositions, materials, components, elements, features, integers, operations and / or process steps that do not substantially affect the basic and novel characteristics may be included in the embodiment.

[0039] Unless specifically identified as an order of performance, any method steps, processes, and operations described herein should not be construed as necessarily requiring their performance in the particular order discussed or illustrated. It should also be understood that additional or alternative steps may be employed unless otherwise specified.

[0040] When a component, element, or layer is referred to as being "on another component or layer," "engaged to another component or layer," "connected to another component or layer," or "coupled to another component or layer," it may be directly on, engaged, connected, or coupled to another component, element, or layer, or there may be intervening elements or layers. Conversely, when an element is referred to as being "directly located at," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0041] Although the terms first, second, third, etc. can be used to describe various steps, elements, components, regions, layers and / or sections in this article, unless otherwise specified, these steps, elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish a step, element, component, region, layer or section from another step, element, component, region, layer or section. Unless the context clearly indicates, when used in this article, terms such as "first", "second" and other numerical terms do not mean order or sequence. Therefore, the first step, element, component, region, layer or section discussed below can be referred to as the second step, element, component, region, layer or section without departing from the teaching of the exemplary embodiment.

[0042] For ease of description, spatially or temporally relative terms, such as "before", "after", "inside", "outside", "below", "under", "down", "above", "upper", etc., may be used herein to describe the relationship of one element or feature to another (one or more) elements or features, as shown in the figures. Spatially or temporally relative terms may also be intended to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.

[0043] Throughout this disclosure, numerical values ​​represent approximate measures or limits of ranges to include minor deviations from given values, and embodiments with approximately the values ​​mentioned, as well as embodiments with exactly the values ​​mentioned. In addition to the working examples provided at the end of the detailed description, all parameter values ​​(e.g., parameter values ​​of quantities or conditions) in this specification (including the appended claims) should be understood to be modified by the term "approximately" in all cases, regardless of whether "approximately" actually appears before the numerical value. "Approximately" means that the numerical value allows some minor imprecision (some close to the exact value in the value; close to or reasonably close to the value; almost). If the imprecision provided by "approximately" is not understood in the art to have such a common meaning, then the "approximately" used herein at least represents the possible changes in the common methods of measuring and using the parameter. For example, "approximately" can include less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5% and in some aspects, optionally less than or equal to 0.1% of the change.

[0044] Furthermore, disclosure of ranges includes disclosure of all values ​​within the entire range and further divided ranges, including endpoints and sub-ranges of a given range.

[0045] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0046] In various aspects, the present disclosure relates to hybrid stator core components for axial flux motors. It will be appreciated that these concepts are applicable not only to axial flux electric motors that generate mechanical energy from electrical energy, but also to axial flux generators that can generate electrical energy from mechanical energy. Figure 1 A non-limiting example of an electrical device in the form of an axial flux motor 100 (also referred to as a flat motor) is shown in FIG. The motor 100 has a first rotor 110 and a second rotor 120, both of which are connected to a rotor shaft 130 and configured to rotate about the rotor shaft 130. The first rotor 110 and the second rotor 120 both have an annular or disc shape and have a centrally disposed hole 118. The rotor shaft 130 passes through the centrally disposed hole 118. The rotor shaft defines an axis of rotation 132 about which the rotors rotate.

[0047] The stator 140 is disposed between the first rotor 110 and the second rotor 120. The stator 140 may have an annular or disc shape. The stator 140 is fixed and stationary, while the first rotor 110 and the second rotor 120 rotate together with the rotor shaft 130 during operation. The first rotor 110 faces a first side 142 of the stator 140 and defines a first air gap 144 therebetween. The second rotor 120 faces a second side 146 of the stator 140 and defines a second air gap 148 therebetween.

[0048] Although the motor 100 is shown as having a central single stator 140 and two outer rotors 110, 120, as will be appreciated by those skilled in the art, other configurations are also contemplated. These other variations may include variations having two stators and a single rotor, or variations in which the electric motor assembly includes more or fewer rotors and / or stators. The following description also applies to these other embodiments. In addition, although not currently shown, those skilled in the art will appreciate that in various aspects, the electric motor assembly may further include a housing, and the rotor and stator and the shaft may be disposed within the housing. In some aspects, the housing may be fixed to the frame, and the shaft may be coupled to a gearbox within the vehicle, such as a reduction gearbox.

[0049] Each of the first rotor 110 and the second rotor 120 can have the same design (facing the stator 140 in opposite directions), and therefore common components will be described herein. Each of the first rotor 110 and the second rotor 120 includes a plurality of permanent magnets 112 attached to a rotor body 114. The permanent magnets 112 can have alternating polarities. Each permanent magnet 112 defines a channel 116 between them, and the channel 116 can extend radially along the face of the corresponding rotor. In this way, the permanent magnets 112 and the channels 116 can define a plurality of magnetic poles together.

[0050] The stator 140 includes a plurality of stator segments or core members 150 around which a plurality of conductive windings 152 are wound. The stator 140 defines a plurality of slots 156 between respective stator core members 150, wherein the conductive windings 152 may extend over or bridge the slots 156. The stator 140 may be fixed and stationary. Although not shown, other winding configurations and techniques understood in the art may also be contemplated. For example, in certain aspects, the slots 156 may be configured to receive a plurality of conductive windings 152 that are wound in and through the slots 156. The wires or windings 152 may include copper or a copper alloy.

[0051] The rotor shaft 130 may pass through a centrally disposed hole 154 in the stator 140 and be supported by a bearing that aligns the rotors 110, 120 relative to the stator 140 while allowing the rotor shaft 130 to rotate. The plurality of conductive windings 152 of the stator 140 may be formed of copper or other conductive wires configured to generate a magnetic field when current is applied to interact with the magnetic fields of the plurality of permanent magnets 112 having alternating magnetic poles located on the first and second rotors 110, 120. Different regions of the stator 140 may be selectively energized to exert a rotational force on the first and second rotors 110, 120, causing the rotors 110, 120 and the rotor shaft 130 to rotate relative to the axis of rotation 132. An axial flux motor 100 having a single stator 140 and first and second rotors 110, 120 can be used in high torque applications, including for electric or hybrid vehicles. In this variation, the housing surrounding motor 100 may be attached to the vehicle frame and at least one output from the end of rotor shaft 130 coupled to a reduction gearbox or directly to the vehicle drive wheels. The vehicle application of axial flux motor 100 is provided as an exemplary embodiment and is not intended to be limiting.

[0052] Figure 2-4 A stator core component that can be used in an axial flux motor stator is shown, similar to Figure 1 The stator 140 in the embodiment of the present invention. The wire is arranged or wound on the outside of the stator. Figure 2 A laminated stator core component 200 is shown having a plurality of layers 210 of magnetic material, such as a ferromagnetic material like magnetic steel. Other magnetic materials may include ferrimagnetic materials. Such layers of magnetic material are typically isolated from one another by insulating material interlaced therebetween. Laminated steel sheets may be stamped, optionally annealed, and stacked during the manufacturing process to form a laminated stator core component. When a plurality of laminated stator core components are assembled together, they form a plurality of magnetizable poles. As can be seen, the stator core component may be an assembly of a plurality of different laminated layer structures or modules, which may have different orientations relative to one another. In other aspects, a plurality of laminated modules may have substantially the same orientation relative to one another. Although in Figure 2 200, each pole defined by the stator core segment 200 will have a conductive wire at least partially disposed or wound around it. When incorporated into the stator of an axial flux motor, such a laminated stator core segment 200 has the advantages of reducing eddy currents and minimizing hysteresis. However, the stator core segments are typically of complex shape. For example, as in Figure 2As can be seen, the first layer 212 has a first dimension defined by its length, width, and height (e.g., thickness), while the second layer 214 in the stack has a second dimension defined by its length, width, and height (e.g., thickness). Due to the substantially trapezoidal shape of the stator core segment 200, the second dimension of the second layer 214 is necessarily less than the first dimension of the first layer 212. Therefore, manufacturing multiple laminated stator core materials, each layer having different dimensions and potentially different shapes, can make the manufacturing process significantly more complicated and can generate a large amount of waste.

[0053] Figure 3-4 Another option for forming a stator core component is shown, in which the stator core component 220 is formed of a soft magnetic composite (SMC) material 222. The SMC powder includes a soft magnetic material, the surface of which may be covered with an electrical insulating layer. These powders are consolidated by pressing or consolidation to form soft magnetic components. Therefore, this SMC material 222 can be easily formed into a variety of different and complex shapes, like the basic trapezoidal cross-sectional shape shown. The stator core component 220 optionally has one or more flanges 224 defining a recessed area 226. Figure 4 A plurality of stator core segments 220 are shown assembled circumferentially on a stator disk 230. A plurality of channels 232 are defined between each stator core segment 220. Figure 4 As shown, the recessed area 226 is configured to receive at least one conductive wire or winding 234 disposed therein (e.g., by being wound around at least a portion of an exterior 236 of the stator core segment 220). Although the stator core segment 220 formed from the SMC material 222 may be easily manufactured into a variety of complex shapes, the stator core segment 220 may potentially generate undesirable eddy currents when incorporated into the stator of an axial flux motor and may have increased hysteresis.

[0054] In various aspects, the present disclosure provides a hybrid stator core component for an axial flux motor stator. Figure 5 In one variation shown, the hybrid stator core component 250 includes a laminate component and a molded soft magnetic composite component to improve the performance of the stator core component and the ease of manufacturing. Therefore, the hybrid stator core component 250 includes a laminate insert 260 in the central region 252 and a molded soft magnetic composite material 270 disposed around the laminate insert 260 to define at least a portion of the outer portion 254 of the hybrid stator core component 250.

[0055] The laminated insert 260 includes a plurality of layers 262. The sheet-forming layers 262 may include ferromagnetic material, and each sheet-forming layer 262 may have at least one insulating layer or coating disposed therebetween. Suitable ferromagnetic materials for laminated stator core components are known in the art and include magnetic steel, as non-limiting examples. The insulating material interlaced between respective layers of the plurality of layers 262 may be a non-magnetic material. As non-limiting examples, the insulating material may include a siloxane-based material, like a silicone varnish, or a metal organic or inorganic insulating material, such as a silicate layer, an oxide layer, a phosphate layer, and equivalents and combinations thereof.

[0056] As shown, each sheet or layer 262 forming a plurality of layers 262 has a substantially identical footprint to other layers 262, for example, having substantially the same size, including the same width, length and thickness, while taking into account manufacturing deviations and tolerances. Therefore, each layer in a plurality of insulating layers can be understood to have substantially the same size. As mentioned herein, when the term "substantially" is applied to the characteristics of the described element, it means that the characteristic may have a slight change beyond the precise specification (for example, due to the change caused by manufacturing tolerances), without having a substantial effect on the mechanical or physical properties of the element. A laminated plug-in 260 having a plurality of layers 262 of the same size can define a rectangular cross-sectional shape. In some aspects, a laminated plug-in 260 having a rectangular cross-sectional shape can define a three-dimensional cube or cuboid. In this way, the manufacture of the laminated plug-in 260 is simplified, wherein each of the plurality of layers 262 has the same standard size and shape. In some aspects, the thickness range of each layer of the plurality of layers 262 is from greater than or equal to about 0.1 mm to less than or equal to about 0.5 mm. As will be appreciated by those skilled in the art, the size / dimensions of the plurality of layers 262 depend on the size of the motor and the size of the stator core and may vary accordingly. In certain variations, the total volume of the hybrid stator core component filled with laminated steel may be in the range of greater than or equal to about 10 volume % to less than or equal to about 90 volume %.

[0057] The periphery 264 or circumferential region of the laminate insert 260 is at least partially surrounded by the molded soft magnetic composite material 270 component. Notably, the hybrid stator core component 250 defines a first side or outer surface 256 and a second side or outer surface 258. The three-dimensional laminate insert 260 defines six sides. Although a portion of the periphery of the laminate insert 260 is surrounded by the molded soft magnetic composite material 270 (i.e., surrounded on four of the six sides), it is noted that two sides of the laminate insert 260 can be exposed on the first outer surface 256 and the second outer surface 258 (i.e., surrounded on four of the six sides). Figure 5). Thus, the laminate insert 260 may define a first central region 266 of the first outer surface 256 and a second central region (not shown) of the second outer surface 258 of the hybrid stator core component 250 .

[0058] The laminate insert 260 and the molded soft magnetic composite material 270 are integrally formed with each other. The molded soft magnetic composite material 270 is molded around the laminate insert 260. For example, after manufacturing, the laminate insert 260 can be set in a mold having a predetermined shape (e.g., as a molded insert) that will define the hybrid stator core component 250.

[0059] The precursor of the soft magnetic composite material can include, for example, ferromagnetic powder particles and an optional matrix material, such as a polymer resin. The (one or more) precursors can be introduced into a mold and fill the area around the laminated plug-in 260 disposed therein. The precursor of the soft magnetic composite material can be densified, for example, by applying a compressive force to the mold. In some aspects, the pressure applied can be greater than or equal to about 1000 MPa. In addition, as required, additional heat and / or actinic radiation can be applied to react the matrix, such as polymerization or cross-linking. In some variations, in order to enhance the adhesion of the laminated plug-in to the molded soft magnetic composite material, an adhesive or glue can be further used at the interface between them.

[0060] In some aspects, the precursor of the molded soft magnetic composite material 270 includes particles defining a magnetic core surrounded by one or more insulating layers in a shell region. The magnetic material in the core can be ferromagnetic and include iron (e.g., iron or ferrite powder) or other magnetizable materials or alloys, including, for example, iron alloys containing silicon, nickel and / or phosphorus (as an example). Other examples include rare earth metal compounds, such as compounds containing samarium (Sm), neodymium (Nd), like samarium cobalt (SmCo 1:5), samarium cobalt (SmCo 2:17) and neodymium iron boron (NdFeB). Other examples of suitable magnetic particles include aluminum nickel cobalt (AlNiCo) alloys. In some aspects, the average particle size of the magnetic particles can be greater than or equal to about 50 microns to less than or equal to about 250 microns, and in some aspects, optionally about 100 microns. The core region including the magnetic material may be surrounded by one or more insulating layers, which are non-magnetic materials, such as siloxane-based materials, like silicone varnish, or metal organic or inorganic insulating materials, for example silicate layers, oxide layers, phosphate layers, and their equivalents and combinations. In some aspects, the (one or more) insulating shell layers can have a total thickness of greater than or equal to about 10 nanometers to less than or equal to about 1 millimeter, and in some aspects, optionally greater than or equal to about 10 nanometers to less than or equal to about 800 microns.

[0061] Additionally, if necessary, a binder layer may serve as a matrix to help individual particles adhere to each other. The binder or matrix may include a thermosetting or thermoplastic polymer, such as an elastomer or polytetrafluoroethylene, or alternatively, a wax (as an example).

[0062] A relatively high pressing pressure is used to press and consolidate the precursor SMC powder to form the molded soft magnetic composite 270. While it is densified and compressed, it should be noted that the molded soft magnetic composite 270 is not sintered.

[0063] In this manner, the molded soft magnetic composite material 270 can be integrally formed around the laminate insert 260, which is non-releasably positioned within the molded soft magnetic composite material 270. Thus, the laminate insert 260 and the molded soft magnetic composite material 270 together form an integral single hybrid stator core component 250. It is advantageous to be able to mold the outer portion 254 of the hybrid stator core component 250 to form complex shapes, such as Figure 5 As shown, the cross-sectional shape is substantially trapezoidal. As shown, the hybrid stator core component 250 defines an outer surface 272 having two flanges 274, which together define a recessed area 276. As described above, the recessed area 276 is configured to receive a wire conductor or winding (not shown). In addition, as will be appreciated by those skilled in the art, the hybrid stator core component 250 is not limited to the design shown, but can have a variety of other shapes and configurations for receiving at least a portion of one or more wire windings or conductors. The hybrid stator core thus formed provides the advantages of manufacturing complex stator core component shapes while advantageously improving performance by reducing eddy currents and hysteresis caused by the presence of an integrated laminated core insert.

[0064] exist Figure 5 , the hybrid stator core segment 250 may be oriented relative to a stator shaft (not shown) that defines a rotational axis 280. As described above, in an axial flux motor, the magnetic flux generated during operation is parallel to the rotational axis 280. Figure 5 As shown, the plurality of layers 262 in the laminated insert 260 each define a major plane (defined by the width and length defining the major surface). The major planes of each of the plurality of layers 262 are parallel to each other. In the design of the laminated insert 260, the major planes of the plurality of layers 262 are substantially parallel to the rotation axis 280.

[0065] Figure 6 Another variation of a hybrid stator core component 290 is shown, similar to Figure 5, but according to other aspects of the present disclosure, the layers in the laminated insert have different orientations relative to the axis of rotation. The hybrid stator core component 290 includes a laminated insert 292 and a molded soft magnetic composite material 294. The laminated insert 292 includes a plurality of layers 296, each of which defines a major plane that is parallel to each other. The hybrid stator core component 290 defines an elongated length 298 (such as a length). In the design of the laminated insert 292, the major planes of the plurality of layers 296 are substantially perpendicular to the elongated length 298.

[0066] In further aspects, the present disclosure contemplates a hybrid stator core component having a central region including an assembly of a plurality of laminate inserts integrally formed with a molded soft magnetic composite component. Figure 7 Such a hybrid stator core component 300 is shown. The insert assembly 310 includes a plurality of different laminate inserts 312. Each laminate insert 312 itself includes a plurality of different ferromagnetic material layers 314. Each sheet or layer 314 has substantially the same footprint / size as the other layers 314 within its respective laminate insert 312. The plurality of layers 314 may have the same dimensions as in Figure 5 The same properties as described in the context of the plurality of layers 262 in the laminate insert 260 described in the context of FIG. 31 and are not repeated here for the sake of brevity. Each laminate insert 312 has a plurality of layers 314 of the same size, which can define a rectangular cross-sectional shape. In certain aspects, each laminate insert 312 having a rectangular cross-sectional shape can define a three-dimensional cube or cuboid.

[0067] However, each of the plurality of inserts 312 in the assembly 310 has a different size than the other inserts 312. For example, the first laminate insert 320 at the top of the hybrid stator core component 300 has a first width 322. The second laminate insert 324 at the bottom of the hybrid stator core component 300 has a second width 326. The first width 322 is greater than the second width 326. Figure 7 In a variation of the present invention, each of the plurality of inserts 312 has a different size than an adjacent insert 312. Figure 7 , but depending on the desired shape of the laminate inserts in the central region of the hybrid stator core component, some individual inserts in the plurality of inserts may have the same size as the other inserts. However, as shown, the hybrid stator core component 300 has five different laminate inserts 312, each of which has a different size. It should be noted that the laminate insert assembly is not necessarily limited to the following. Figure 7The number or orientation of the inserts 312 shown. Notably, each respective plurality of different ferromagnetic material layers 314 (in each respective insert of the plurality of inserts 312) share a uniform size and shape (e.g., each different layer 314 has the same footprint or size as the other layers), which simplifies manufacturing and reduces waste when forming a standard laminate insert. In addition, laminations of different thicknesses or mixed combinations of different thicknesses, as well as oriented and non-oriented laminations, may be selected.

[0068] As shown, the plurality of layers 314 in each laminate insert 312 define major planes that are parallel to one another. The hybrid stator core component 300 defines an elongated length 330 (such as a length). For each laminate insert 312 in the assembly 310 , the major planes of the plurality of layers 314 are parallel to the elongated length 330 .

[0069] The molded soft magnetic composite material 340 is molded around a plug-in assembly 310 including a plurality of different laminated plug-ins 312. The molded soft magnetic composite material 340 defines an outer region of the hybrid stator core component 300. For example, after manufacturing, the plug-in assembly 310 can be disposed in a mold having a predetermined shape (e.g., as a molded plug-in) that will define the hybrid stator core component 300, and the molded soft magnetic composite material 340 is compressed and molded around the plug-in assembly 310. Thus, the molded soft magnetic composite material 340 fills the voids around the plug-in assembly 310, and after molding, surrounds and contacts various surfaces of the plug-in assembly 310, such that the plug-in assembly 310 and the molded soft magnetic composite material 340 are integrally formed with each other. Figure 7 In the illustrated embodiment, the hybrid stator core segment 300 thus has a significant portion of its overall volume filled with laminate inserts, which serves to help improve performance by further reducing hysteresis.

[0070] Figure 8 Another hybrid stator core component 350 is shown. The insert assembly 360 includes a plurality of different laminate inserts 362. Each laminate insert 362 itself includes a plurality of different ferromagnetic material layers 364. Each sheet or layer 364 has substantially the same footprint / size as the other layers 364 in its corresponding laminate insert 362. The multiple layers 364 may have the same size as in Figure 5 The same properties as described in the context of the multiple layers 262 in the laminate insert 260 described in the context of , and for the sake of brevity, are not repeated here. Each laminate insert 362 has multiple layers 364, and these layers 364 have the same size, and each laminate insert can define a rectangular cross-sectional shape. In some aspects, each laminate insert 362 with a rectangular cross-sectional shape can define a three-dimensional cube or cuboid.

[0071] However, selected ones of the plurality of inserts 362 in the assembly 360 may have different dimensions than the other inserts 362. Figure 8 , assembly 360 includes three laminate inserts 362, namely a first laminate insert 370, a second laminate insert 372, and a third laminate insert 374. The first laminate insert 370 and the second laminate insert 372 have the same dimensions, including width, length, and height. However, the third laminate insert 374 can deviate from the dimensions of the first laminate insert 370 and the second laminate insert 372, for example, having a different and longer length. For example, the first laminate insert 370 and the second laminate insert 372 can have a first length 376, and the third laminate insert 374 can have a second length 378 that is greater than the first length 376. Although three inserts 362 are shown in assembly 360, Figure 7 As with another embodiment having a laminated insert assembly shown in , such an assembly need not be limited to the number or orientation of inserts 362 shown. Likewise, in a given laminate insert 362, each of the corresponding plurality of insulating layers 364 of ferromagnetic material has a uniform size and shape. This uniformity simplifies manufacturing and reduces waste when forming a standard laminate insert.

[0072] As shown, the plurality of layers 364 in each laminate insert 362 define major planes that are parallel to one another. The hybrid stator core component 350 defines an elongated length 380 (such as a length). For each laminate insert 362 in the insert assembly 360 , the major planes of the plurality of layers 364 are perpendicular to the elongated length 380 .

[0073] The molded soft magnetic composite material 390 is molded around a plug-in assembly 360 including a plurality of different laminated plug-ins 362. The molded soft magnetic composite material 390 defines an outer region of the hybrid stator core component 350. For example, after manufacturing, the plug-in assembly 360 can be disposed in a mold having a predetermined shape (e.g., as a molded plug-in) that will define the hybrid stator core component 350, and the molded soft magnetic composite material 390 is compressed and molded around the plug-in assembly 360. The molded soft magnetic composite material 390 fills the voids around the plug-in assembly 360. After the molding process, the molded soft magnetic composite material 390 surrounds and contacts various surfaces of the plug-in assembly 360, so that the plug-in assembly 360 and the molded soft magnetic composite material 390 are integrally formed with each other. As shown in Figure 5 As described in the context of , although four sides of the insert assembly 360 may be surrounded by the molded soft magnetic composite material 390, two sides of the insert assembly 360 may form a portion of the exposed or outer surface of the hybrid stator core component 350. Figure 8 In the illustrated embodiment, the hybrid stator core segment 350 thus has a significant portion of its overall volume filled with laminate inserts, which serves to help improve performance by further reducing hysteresis.

[0074] Fig. 9Yet another variation of a hybrid stator core component 400 for an axial flux motor stator prepared in accordance with the present disclosure is shown. It is noteworthy that the size of the gap shown is for illustrative purposes only and is not to scale with actual size or dimensions. The hybrid stator core component 400 has a molded soft magnetic composite core 410 in a central region 412. The shell region 414 includes a plurality of ferromagnetic material layers 420, such as those previously described above in the context of multiple ferromagnetic material layers in a laminate insert. As described above, in certain aspects, the multiple layers 420 can be insulated with insulating material 422 disposed between respective layers of the multiple layers 420, the insulating material 422 being similar to the non-magnetic insulating material previously described above. As shown, the ferromagnetic material can be a single piece that is wound or wrapped multiple times around the molded soft magnetic composite core 410, and can therefore be considered to define multiple layers in a radially outward direction from the central region 412 (although the ferromagnetic material forming the multiple layers 420 can be the same single piece). The molded soft magnetic composite core 410 may be formed into any number of predetermined shapes that facilitate subsequent winding or wrapping of the plurality of layers 420 around a shell region 414 corresponding to the exterior of the hybrid stator core segment 400. Thus, the laminate shell including the plurality of layers of ferromagnetic material may define an exterior surface of the hybrid stator core segment 400, which may further define other features, such as at least one recessed region configured to receive a wire winding.

[0075] An example of a wire winding 430 is shown wound around the housing region 414 of the hybrid stator core segment 400. Fig. 9 As shown, one or more layers of insulating material 432 may be disposed between the plurality of laminated layers 420 and the wire windings 430. Again, the insulating material 432 may be any of the examples previously described above. The hybrid stator core component 400 thus provides an integrally formed molded soft magnetic composite core region and a plurality of ferromagnetic material insulating layers forming a shell region, providing a combination of these materials that is used to enhance performance by reducing eddy currents and / or hysteresis.

[0076] Therefore, the present disclosure provides a hybrid stator core component for an axial flux motor stator, which includes a molded soft magnetic composite material and a laminate component formed integrally with each other. In one variation, the laminate component is a laminate plug-in including a plurality of insulating layers, the insulating layers including ferromagnetic material. The molded soft magnetic composite material is arranged around a portion of the periphery of the laminate plug-in, wherein the laminate plug-in is non-releasably located within the molded soft magnetic composite material. In other variations, the hybrid stator core component has a molded soft magnetic composite core and a laminate shell arranged around at least a portion of the molded soft magnetic composite core, the laminate shell including a plurality of layers, and the plurality of layers including ferromagnetic material.

[0077] In certain variations, the present disclosure contemplates an axial flux motor comprising a stator comprising a plurality of hybrid stator core segments, such as described above in Figure 5-9 Any of those components described in the context of . Each hybrid stator core component has a wire arranged around its exterior. The axial flux motor also includes a rotor facing the stator. The rotor may include a plurality of magnets. In addition, the stator and the rotor define an air gap therebetween. There is also a rotor shaft that is coupled to the rotor and defines an axis of rotation. In certain variations, a plurality of insulating layers in each hybrid stator core component may define a main plane. In addition, the hybrid stator core may define an elongated length. Each of the plurality of insulating layers defines a main plane that is parallel to each other. In certain aspects, each main plane may be parallel to the elongated length or perpendicular to the elongated length. In other variations, the main plane defined by the layer may not necessarily be parallel to or perpendicular to the drawn elongated length, but may be an angle other than 0° or 90°. Therefore, although the main plane may be horizontal, vertical, or inclined when viewed from the front or rear of the core, in certain aspects, the main plane of the layer is parallel to the axis of rotation. A parallel orientation may be advantageous because the magnetic flux generally does not cross the insulating layers between magnetic layers (eg silicon steel) since they are also ideally parallel to the main plane.

[0078] In other aspects, the present disclosure provides a method for manufacturing a hybrid stator core component for an axial flux motor stator. The applied pressure may be greater than or equal to about 1000 MPa. The method may include arranging a laminated plug-in in a mold, the laminated plug-in having a plurality of insulating layers, the insulating layers comprising a ferromagnetic material. The mold may have a predetermined shape corresponding to the hybrid stator core component. A precursor of a soft magnetic composite material may then be introduced into the mold. The precursor may be similar to those previously described above, and may include a plurality of magnetic particles, each of which has an insulating coating. Pressure (optionally accompanied by heating) may be applied to mold the precursor into a soft magnetic composite material that surrounds a portion of the periphery of the laminated plug-in. In certain aspects, in the presence of an adhesive or matrix between the particles, the precursor may be exposed to actinic radiation, or the binder may be otherwise induced to react or crosslink. In addition, in certain aspects, the laminated plug-in may be attached to the molded SMC with an adhesive or glue or other method, for example, by applying an adhesive before the precursor of the soft magnetic composite material is introduced into the mold. In this way, the laminated plug-in is non-releasably located within the molded soft magnetic composite material. As noted above, in certain variations, the laminate insert is a plurality of laminate inserts forming an insert assembly.

[0079] In other aspects, the method may include forming the laminate insert prior to disposing. The laminate insert may be made by stamping or cutting each layer from a sheet of ferromagnetic material and stacking the layers together. As described above, the sheet of ferromagnetic material may have a coating of insulating material disposed on at least one surface prior to stamping or cutting, or the insulating material may be applied after stamping or cutting, or interleaved as a separate material during the stacking process.

[0080] In other aspects, the present disclosure provides a method for manufacturing a hybrid stator core component for an axial flux motor stator. The method may include forming a core region of a molded soft magnetic composite. A precursor of the soft magnetic composite may be introduced into a mold, which may have a predetermined shape corresponding to the desired shape of the core region. As previously described, the precursor may include a plurality of magnetic particles, each of which has an insulating coating. Pressure (optionally accompanied by heating) may be applied to mold the precursor into a soft magnetic composite that will define the core region of the hybrid stator core component. In certain aspects, when a binder or matrix is ​​present between the particles, the precursor may be exposed to actinic radiation, or the binder may be otherwise caused to react or crosslink. The core comprising the molded soft magnetic composite may be removed from the mold.

[0081] Next, at least one sheet of ferromagnetic material is wound or wrapped around the exterior of the molded soft magnetic composite core. In this manner, the sheet(s) of ferromagnetic material form multiple layers. As described above, the sheet may have an insulating coating applied prior to the assembly process, or may be stacked with the insulating layer(s) such that as it is wound around the core region, the insulating layers are formed between the layers of ferromagnetic material. In this manner, an integrally formed hybrid stator core component is formed having a core region comprising a molded soft magnetic composite material and a laminated shell comprising an insulating layer of ferromagnetic material.

[0082] The foregoing description of the embodiments has been provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. The individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in selected embodiments, even if not specifically shown or described. The embodiments may also differ in many ways. These changes should not be considered as departing from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A hybrid stator core component defining magnetic poles for an axial flux motor stator, the hybrid stator core component comprising: a bottom portion defining an inner circumferential surface and a top portion defining an outer circumferential surface; a first side and an opposite second side, each of the first side and the second side extending in a radial direction between the bottom and the top; a molded soft magnetic composite core disposed in a central region between the bottom and top and between the first side and the second side; and a laminate shell comprising a plurality of layers, the plurality of layers comprising ferromagnetic material, the laminate shell being disposed around at least a portion of the molded soft magnetic composite core, wherein an insulating material is disposed adjacent to at least one of the plurality of layers, wherein the laminate shell defines at least a portion of the inner circumferential surface, the outer circumferential surface, the first side, and the second side. 2 . The hybrid stator core component of claim 1 , wherein an insulating material is disposed adjacent to at least one of the plurality of layers.

3. The hybrid stator core component of claim 1, wherein the first side defines a first recessed area and the second side defines a second recessed area, wherein the first recessed area and the second recessed area are configured to receive a wire winding wrapped around at least a portion of an exterior of the hybrid stator core component.

4. The hybrid stator core component according to claim 1, wherein: The ferromagnetic material includes steel, and the soft magnetic composite material includes a plurality of magnetic particles including iron.

5. An axial flux motor comprising: A stator comprising a plurality of hybrid stator core components according to any one of claims 1 to 4, wherein the plurality of hybrid stator core components are positioned adjacent to each other along the circumference of the stator such that a channel is defined and extends between each pair of adjacent hybrid stator core components in a radial direction; a rotor facing the stator and including a plurality of magnets, wherein the stator and the rotor define an air gap therebetween; and at least one rotor shaft coupled to the rotor and defining an axis of rotation, A wire winding is wound around the exterior of each of the plurality of hybrid stator core components.

6. A method of manufacturing a hybrid stator core component for an axial flux motor stator, comprising: forming a core region of a molded soft magnetic composite, introducing a precursor of the soft magnetic composite into a mold, the mold having a predetermined shape corresponding to a desired shape of the core region, wherein the precursor comprises a plurality of magnetic particles, each magnetic particle having an insulating coating, applying pressure to mold the precursor into the soft magnetic composite that will define the core region of the hybrid stator core component; and At least one sheet of ferromagnetic material is rolled or wound around the exterior of the molded soft magnetic composite core to form an integrally formed hybrid stator core component having a core region including molded soft magnetic composite material and a laminate shell including an insulating layer of ferromagnetic material.

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