Double Stator Core with Amorphous Metal Integration
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Solution Overview
Problem
Conventional electric motors face challenges in achieving high-speed, high-power, and high-efficiency operations due to core losses and manufacturing complexities, particularly with amorphous metal magnetic members, which are brittle and difficult to fabricate into bulk magnetic components for stators and rotors.
Innovation Solution
A double stator configuration combining a lamination type core and a compressed powder magnetic core, where the stator core is formed by compression-molding amorphous metal powders or soft magnetic powders, with integration type core portions and a lamination type core portion, allowing for reduced core losses, simplified manufacturing, and increased magnetization strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If amorphous metal ribbons are used to form bulk magnetic members, then magnetic performance is improved, but manufacturing difficulty and cost increase due to brittleness and processing challenges
Solution Approach 1:
The stator core is divided into multiple thin lamination plates stacked together, with amorphous metal strips embedded within the slots. This segmentation allows the brittle amorphous metal to be used in a manageable form while maintaining structural integrity and reducing manufacturing complexity.
Solution Approach 2:
The patent creates a composite structure combining lamination plates made of conventional magnetic material with embedded amorphous metal strips. This composite approach leverages the excellent magnetic properties of amorphous metal while using conventional materials for structural support, resolving the manufacturing difficulty.
2Ease of manufacture
If lamination plates are stacked to form stator core, then manufacturing is simplified, but core losses increase at high frequencies
Solution Approach 1:
The patent applies different material qualities to different locations: conventional lamination plates form the structural framework, while amorphous metal strips with superior magnetic properties are placed in the magnetic flux paths within slots. This local quality differentiation reduces core losses at high frequencies while maintaining manufacturing simplicity.
3Shape
If amorphous metal ribbons are cut and molded, then magnetic component shape is achieved, but brittleness causes durability concerns
Solution Approach 1:
Instead of forming large monolithic components from brittle amorphous metal, the patent segments the amorphous metal into thin strips that are embedded within the lamination structure. This segmentation reduces stress concentrations and improves durability while achieving the required component shape.
Solution Approach 2:
The lamination plates provide structural support and cushioning to the embedded amorphous metal strips beforehand, preventing the brittle strips from undergoing excessive stress during operation. This prior cushioning enhances the reliability of the amorphous metal components.
4Speed
If high-speed operation is implemented, then motor speed increases, but core losses generate excessive heat
Solution Approach 1:
The patent uses a composite structure with amorphous metal strips embedded in lamination plates. The amorphous metal's superior magnetic properties reduce hysteresis losses at high frequencies, while the conventional lamination structure provides eddy current shielding, together reducing heat generation during high-speed operation.
Solution Approach 2:
The patent places amorphous metal strips specifically in regions with high magnetic flux density within the stator slots, where they provide local improvement in magnetic performance and reduce core losses. This local quality enhancement targets the heat generation problem at its source.
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 configuration enables the creation of a high-power, high-speed, and high-efficiency motor with a thin structure, reducing manufacturing costs and improving productivity while minimizing core losses and weight, making it suitable for applications like drive motors for electric vehicles and washing machines.
Implementation Method 1
a stator core comprising: a lamination type core portion that is formed by laminating a plurality of iron pieces
Implementation Method 2
a double stator having a configuration of a hybrid type stator core that is formed by combining a lamination type core and a compressed powder magnetic core
Data Source
AI summary
A double stator includes: a stator core; a bobbin wrapped on an outer circumferential surface of the stator core; and a first coil wound on one side of the stator core and a second coil wound on the other side of the stator core. The stator core includes: a lamination type core portion formed by laminating a plurality of iron pieces, on an outer surface of which a first press-fit groove is formed, and on an inner surface of which a second press-fit groove is formed; a first integration type core portion fixed to the first press-fit groove of the lamination type core portion, integrally formed by metal powders, and on which a first coil is wound; and a second integration type core portion fixed to the second press-fit groove of the lamination type core portion, integrally formed by metal powders, and on which a second coil is wound.