Design of electric motor parts with thermoplastic composite materials with magnetic properties

Abstract

This invention represents a significant advance in the field of electric motors. It involves a motor designed with innovative raw materials, specifically magnetic thermoplastic composites, which replace the traditional rotor and stator components. Thermoplastic composites are often considered as a viable alternative to metallic magnetic materials, as they offer a lighter weight and can replace the magnetic properties of existing materials. The invention also offers a perspective on traditional components such as the core, generator and electrical connections. By integrating materials science with technological advances in electric motor design, it offers a more efficient and innovative structure. These materials not only fulfill the magnetic properties of the motor, but also enable more complex and optimised designs. When used in electric motors, these innovative materials can improve energy efficiency, enable lighter and more compact motor structures, and contribute to the cost-effectiveness of manufacturing processes. As a result, magnetic thermoplastic composites has the potential to improve the sustainability and competitiveness of electric motor technology.

Description

[0001] DESIGN OF ELECTRIC MOTOR PARTS WITH THERMOPLASTIC COMPOSITE MATERIALS WITH MAGNETIC PROPERTIES

[0002] Technical Field

[0003] This invention represents a significant advance in the field of electric motors. It involves a motor designed with innovative raw materials, specifically magnetic thermoplastic composites, which replace the traditional rotor and stator components. Thermoplastic composites are often considered as a viable alternative to metallic magnetic materials, as they offer a lighter weight and can replace the magnetic properties of existing materials. The invention also offers a perspective on traditional components such as the core, generator and electrical connections. By integrating materials science with technological advances in electric motor design, it offers a more efficient and innovative structure. These materials not only fulfill the magnetic properties of the motor, but also enable more complex and optimised designs. When used in electric motors, these innovative materials can improve energy efficiency, enable lighter and more compact motor structures, and contribute to the cost-effectiveness of manufacturing processes. As a result, magnetic thermoplastic composites has the potential to improve the sustainability and competitiveness of electric motor technology.

[0004] Previous Art

[0005] Magnetism is an effective phenomenon in nature, constituting a fundamental physical property crucial for myriad technological applications. Materials with magnetic properties are indispensable engineering materials employed in automotive, electronic, and medical fields, capitalizing on this principle characteristic. These materials wield — important influence across diverse applications owing to their capability to generate magnetic fields and distinctive attributes linked to the effects of magnetic fields. They assume critical importance in the area of automotive, electronic, and medical engineering materials.

[0006] Magnetic materials are generally classified into four main categories: ferromagnetic, antiferromagnetic, ferrimagnetic, and diaferromagnetic. Iron and nickel are examples of ferromagnetic materials, demonstrating strong magnetic effects and possessing permanent magnet attributes. In antiferromagnetic materials, atoms align in opposite magnetic directions, resulting in a neutral response to magnetic fields. Ferrimagnetic materials are similar to ferromagnetic materials, but the magnetic moments are oriented in opposite directions. Diaferromagnetic materials are typically found in a non-magnetized state.

[0007] Magnetic materials play a fundamental role in various aspects of modern technology. However, there are some significant disadvantages associated with the use of these materials. Particularly in fields where magnetic materials are applied, these drawbacks encourage engineering and technology experts to overcome current limitations and find more efficient solutions. Challenges such as high temperature sensitivity, corrosion susceptibility, power loss, and processing issues represent substantial obstacles in the development and application of magnetic materials. Nevertheless, these disadvantages also present opportunities that can be overcome through new technological innovations and advancements in material science.

[0008] Corrosion is a major concern for many applications involving magnetic materials. Particularly, iron-based magnetic materials may be prone to oxidation over time, reducing the durability and life of the material. Consequently, various coating and corrosion prevention methods continue to be developed to enhance the corrosion resistance of magnetic materials used in sectors such as maritime, automotive, and construction. Research on corrosion was addressed in the Journal of Applied Physics in 2011, as detailed in the article "Study on corrosion behaviors of sintered Nd-Fe-B magnets in different environmental conditions."

[0009] Machinability refers to magnetic materials' formability and workability. Some magnetic materials can be difficult and costly to machine, which is an issue for industries seeking to optimize production processes. Progress is being made in the development of new techniques and manufacturing methods to improve the machinability of magnetic materials. A review titled 'Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review,' published in the Materials journal in 2023, contains up-to-date information on advancements in this field.

[0010] Commonly used primary magnetic materials in electric motors include ferrites and rare-earth magnets. Ferrite magnets are widely used because they cost little and resist corrosion. They are commonly employed in applications such as AC motors, microwave ovens, speakers, and magnetic holders. Ferrite magnets fall into the category of ceramic magnets and are typically composed of a mixture of iron oxide and either barium oxide or strontium oxide. They have low magnetizability, and magnetization occurs under the influence of a constant magnetic field. Such materials are also known as soft magnetic materials. They have high resistivity, resulting in low magnetic losses.

[0011] NdFeB magnets are frequently used in modern electric motors due to their high energy density and excellent magnetic properties. These magnets can be found in applications like computer hard disk drives, electric vehicle motors, and other high- performance systems. NdFeB magnets are composed of neodymium, iron, and boron elements. Their high energy density allows them to generate strong magnetic fields in small volumes. However, ongoing research focuses on recycling and alternative magnet materials due to the limited reserves of rare-earth elements and environmental concerns.

[0012] Magnetic materials play a crucial role in the rotor and stator, the two essential components of electric motors. Cores are used within the stator to enhance or optimize the magnetic field.

[0013] Aim of the Invention

[0014] Magnetic materials are an important part of modern technology and are used successfully in many applications. However, with continuously changing and evolving industrial needs, there is substantial research potential in the field of polymer-based innovative materials for the future of material science. The flexibility, lightweight, and processability of polymers can position them as potential composite magnetic materials. This opens the door to a new era, as polymer-based magnetic materials can offer a diverse range of advantages that have the potential to revolutionize numerous sectors, from electronic devices to medical applications.

[0015] The use of thermoplastic composites with magnetic properties in electric motor components represents a breakthrough in electric motor technology. The unique characteristics of these materials provide comparable performance and design flexibility when compared to traditional materials. The use of these materials in electric motors improves efficiency, leading to energy savings, and enables the development of lighter and more compact motor structures. The use of magnetic thermoplastic materials in electric motor components optimizes manufacturing processes, reducing costs, and contributes to the motor's longevity and durability. Consequently, this opens the way to shaping the future of electric motor technology by offering new solutions in sustainability, energy efficiency, and innovation.

[0016] The use of these innovative materials has the potential to transform industrial design and manufacturing processes. Magnetic thermoplastic composite materials, offering advantages in both cost and processability, can provide more efficient and sustainable solutions in future manufacturing processes.

[0017] Thermoplastic materials can be considered a suitable option for imparting magnetic properties. These materials typically consist of large molecular-weight polymeric compounds, often formed by long molecular chains. Thermoplastic polymers soften within a specific temperature range (typically between 130°C and 360°C) and solidify upon cooling. This distinctive characteristic is a crucial feature that allows thermoplastic polymers to be molded and subsequently reshaped, contributing to their ability to be recycled.

[0018] One of the distinctive features of thermoplastic polymers is their amorphous or crystalline structures. In amorphous polymers, molecular chains are arranged irregularly, typically contributing to the flexibility of the polymer. On the other hand, in crystalline polymers, molecular chains are aligned in a specific order, often providing higher strength and hardness.

[0019] Another distinctive feature of thermoplastic polymers is their melting points. When heated, the attractive forces between molecular chains decrease, causing the polymer to melt. This characteristic allows thermoplastic polymers to be molded and reshaped repeatedly. Additionally, this property provides a significant advantage in the production of innovative materials, enabling the fabrication of thermoplastic composite materials.

[0020] These polymers find widespread use in various applications, including packaging materials, textile fibers, automotive components, medical devices, and a range of industrial applications. The widespread use of thermoplastic polymers is based on advantages such as mouldability, durability and recyclability. The extrusion process is used in the manufacture of thermoplastic matrix magnetic composites where magnetic fillers are added to the thermoplastic matrix. In this process, magnetic particles are commonly integrated into the extrusion process and uniformly distributed throughout the matrix material. Extrusion, which is carried out under high temperature and pressure, allows the material to be shaped and the desired profile to be achieved. Composite materials with magnetic properties produced through extrusion are used in electromagnetic applications, radio frequency tagging systems, and industrial applications requiring electromagnetic compatibility. The advantages of these composite materials include lightweight, excellent processability, low cost, and flexibility for use in various application areas. The extruded thermoplastic matrix of magnetic composite materials can be customized and improved to suit a variety of industrial applications, owing to their unique properties.

[0021] Detailed Description of the Invention

[0022] Thermoplastic based magnetic composites are a distinct class of materials with magnetic particles dispersed within a thermoplastic matrix. These composites balance the flexibility, processability and lightweight of the thermoplastic polymer matrix with the magnetisable properties of the magnetic particles. Magnetic particles, typically with ferromagnetic or ferrimagnetic properties, are homogeneously integrated into the thermoplastic matrix. This integration allows controlled manipulation of the magnetic properties of the material.

[0023] Thermoplastic-based magnetic composite materials have a wide range of potential applications in industrial areas, electromagnetic devices, and magnetic sensors. The production processes for these materials often involve thermoplastic processing methods such as extrusion or injection molding. These processes facilitate shaping the material to suit various form factors. Ultimately, thermoplastic-based magnetic composite materials offer innovation potential across diverse industries by combining the magnetizable properties with the advantages of thermoplastic polymers.

[0024] Polymer-based composite materials typically use at least one type of thermoplastic matrix material, such as Polyethylene (PE), Polypropylene (PP), Polystyrene (PS), Polyethylene terephthalate (PET or PTFE), Polyamide (PA) (Nylon), Polyvinyl chloride (PVC), Polyvinylidene fluoride (PVDF), Polycarbonate (PC), Acrylonitrile butadiene styrene (ABS), Polyvinylidene chloride (PVDC), Polybutylene terephthalate (PBT), Polyphenylene sulfide (PPS), Syndiotactic Polystyrene (SPS), Polyether ether ketone (PEEK), Polyketones (POK), among others, as the thermoplastic matrix.

[0025] Magnetic additives with magnetic properties can be used as reinforcing materials in composite materials. These may include materials such as Ferrite (Iron Oxide), Ferrite-Based Ceramics, Magnetic Nanoparticles, Magnetic Polymers, Nanomagnetic Polymers, Magnetic Metal Powders, Magnetic Ceramic Powders, Magnetic Elastomers, Magnetic Carbon Nanotubes, and Magnetic Biopolymers. Additionally, various additives, fillers, and / or reinforcement materials can be employed to ensure interfacial compatibility in composite materials.

[0026] The main mechanisms involved in an extrusion process are feeding, melting and homogeneous mixing. Twin screw extrusion is a process used to melt and shape thermoplastic materials. In this process, the material is fed through a twin screw extruder and the rotating motion of the screws melts the material. The molten material is then extruded into a flat plane, cooled, shaped and cut. Twin screw extrusion offers advantages such as high production speeds and ensuring homogeneous material properties. The length-to-diameter ratio of the screws (L / D ratio) affects the mixing and homogeneity of the output. The material's exit speed from the extruder is dependent on screw speed, barrel temperature, screw configuration, and melt viscosity.

[0027] Magnetic composite materials can have the same magnetic properties as conventional metal magnets for use in the rotor of an electric motor. The rotor, typically the rotating part of an electric motor, can benefit from the use of magnetic composite materials by optimizing magnetic properties to create a stronger and more energy-efficient rotor compared to traditional metal magnets. This feature has the potential to enhance the efficiency of the motor.

[0028] The stator represents the stationary part of an electric motor and typically contains coils or windings. Magnetic composite materials can fulfill the magnetic properties of the stator, thus creating a similar magnetic field. This interaction with the rotor facilitates the movement of the motor. Additionally, the low density of these materials can contribute to the lightweight nature of the stator, helping to reduce the overall weight of the motor.

[0029] Magnetic composite materials can also be used in the core of the motor. The core is crucial for directing and concentrating magnetic flux. By optimizing the magnetic properties of the core, magnetic composite materials can reduce energy losses and improve the efficiency of the motor. Additionally, the flexibility in the manufacturing processes of these materials allows for the easy implementation of various core designs.

Claims

CLAIMS1. The invention is a 3D printer filament exhibiting magnetic characterized by;- at least one of the thermoplastic matrices, comprising by mass from 20% to 80%: Polyethylene (PE), Polypropylene (PP), Polystyrene (PS), Polyethylene terephthalate (PET or PTFE), Polyamide (PA) (Nylon), Polyvinyl chloride (PVC), Polyvinylidene fluoride (PVDF), Polycarbonate (PC), Acrylonitrile butadiene styrene (ABS), Polyvinylidene chloride (PVDC), Polybutylene terephthalate (PBT), Polyphenylene sulfide (PPS), Syndiotactic Polystyrene (SPS), Polyether ether ketone (PEEK),- at least one of the additives, fillers, and / or reinforcing materials from the following magnetic substances, comprising by mass from 40% to 80%: Ferrite (Iron Oxide), Ferrite-Based Ceramics, Magnetic Nanoparticles, Magnetic Polymers, Nanomagnetic Polymers, Magnetic Metal Powder, Magnetic Ceramic Powder, Magnetic Elastomers, Magnetic Carbon Nanotubes, Magnetic Biopolymers,- a polymer-based composite material containing additives, fillers, and / or reinforcing materials in the composite content, comprising by mass from 1% to 30%.

2. A thermoplastic material with magnetic properties that can be used in motor components, characterized by;- prepared in granular form suitable for material injection molding or in filament form suitable for 3D printers,- usable in the motor as a rotor, stator, and / or core part,- designed to match existing parts and / or thermoplastic composite material in terms of design.