Additive Stator Core with In-Flight Insulation
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Solution Overview
Problem
The fabrication of laminated stator cores for electric machines is complex, labor-intensive, and costly, leading to sub-optimal designs with restricted magnetic circuit configurations and limited cogging reduction, especially in vibration-sensitive applications, due to the constraints of traditional steel laminations and the difficulty in incorporating cooling for increased current density and torque output.
Innovation Solution
A system and method for creating a material with domains having insulated boundaries using a droplet spray subsystem to form molten alloy droplets and a gas subsystem to introduce reactive gases, forming an insulation layer on the droplets, which are then deposited to form a material with insulated boundaries, allowing for improved magnetic properties and reduced eddy current losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional laminated stator cores are constructed by stacking individually laminated thin sheet-metal elements, then eddy current losses are reduced through insulation layers, but the fabrication process becomes complicated, labor-intensive, and costly
Solution Approach 1:
The patent combines multiple separate operations (cutting, insulating, stacking) into a single integrated process by forming the stator core from a single piece of magnetic material using additive manufacturing, eliminating the need for individual lamination and assembly steps while maintaining eddy current loss reduction through built-in insulation features
Solution Approach 2:
The invention changes the fundamental manufacturing approach from subtractive (cutting laminations from sheets) and assembly-based to additive (building the core layer by layer), transforming the process complexity from high to low while enabling integrated insulation structures
2Reliability
If individual sheet-metal elements are coated with insulating layers and assembled, then magnetic flux can be channeled along elements, but the geometry of the motor is considerably constrained
Solution Approach 1:
The patent enables dynamic geometric configuration of the stator core by building it layer by layer using additive manufacturing, allowing the magnetic circuit geometry to be optimized for specific applications without being constrained by lamination stacking limitations
Solution Approach 2:
The invention applies insulation selectively at specific locations and orientations within the magnetic material during additive manufacturing, creating localized insulation features that guide magnetic flux where needed while maintaining geometric flexibility in other areas
3Loss of energy
If laminated stator cores are constructed with insulation layers, then eddy current losses are minimized, but it is difficult to incorporate cooling for increased current density
Solution Approach 1:
The patent segments the stator core into discrete layers during additive manufacturing, creating internal channels and pathways between layers that can be used for cooling fluid flow, thereby enabling heat removal while maintaining the insulating structure needed to minimize eddy current losses
Solution Approach 2:
The invention nests cooling channels within the layered structure of the stator core itself, integrating the cooling system into the core geometry rather than adding separate cooling components, allowing simultaneous achievement of eddy current loss reduction and effective thermal management
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a material with enhanced permeability, low coercivity, and high saturation induction, minimizing eddy current losses and enabling more efficient and cost-effective production of electric machine stator cores with improved magnetic paths and reduced design constraints.
Implementation Method 1
introducing one or more reactive gases proximate the in-flight droplets to create an insulation layer on the droplets
Implementation Method 2
creating molten alloy droplets
Data Source
AI summary
A system for forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material. The systems has a heating device; a deposition device; a support configured to support the soft magnetic bulk material of the predetermined shape; and a mask configured as a negative of at least a portion of the predetermined shape. The heating device heats the magnetic material to form particles having a softened state and wherein the deposition device deposits successive layers of particles of the magnetic material in the softened state on the support with the mask located between the deposition device and the support. The mask is indexed to a position relative to the support upon deposition of the successive layers. The mask selectively blocks the successive layers of particles of the magnetic material in the softened state from being deposited on the support forming the soft magnetic bulk material of a predetermined shape on the support.