Grain-Oriented Soft Magnetic Material for Electromagnetic Flux Path Optimization

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Solution Overview

Problem

Conventional electromagnetic devices, such as motors and transformers, face efficiency and performance issues due to non-aligned metal grains in soft magnetically-conductive materials, which act as flux obstacles, increasing reluctance and losses.

Innovation Solution

The use of strategically oriented metal grains in soft magnetically-conductive materials, aligned with magnetic flux paths, achieved through additive manufacturing and post-processing techniques like laser or electron beam melting, and thermo-mechanical methodologies, to optimize grain orientation and crystallographic texture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If non-grain orientated metal is used in soft magnetically-conductive material, then manufacturing is easier and more cost-effective, but efficiency and performance are reduced due to flux obstacles and increased reluctance

Engineering Contradiction:

Improvemanufacturing easeVSAvoidenergy losses

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent applies local quality by orienting metal grains specifically in regions where flux paths are well-defined and benefit from alignment, while leaving other regions with non-oriented grains. This selective approach optimizes performance in critical areas without requiring complete grain orientation throughout the entire component, thus maintaining manufacturing feasibility while reducing energy losses in flux-critical regions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the physical parameter of grain orientation from random (non-oriented) to aligned (oriented) in specific regions. This parameter change reduces magnetic reluctance and flux obstacles in areas where flux paths are predictable, thereby decreasing energy losses while maintaining ease of manufacture through targeted rather than universal grain orientation.

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If grain oriented metal portions are formed strategically, then efficiency and performance are enhanced by reducing reluctance, but manufacturing complexity increases

Engineering Contradiction:

Improveenergy lossesVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent segments the soft magnetically-conductive material into distinct regions: grain-oriented portions in areas with well-defined flux paths and non-grain-oriented portions in other areas. This segmentation allows grain orientation to be applied only where it provides the most benefit, reducing overall manufacturing complexity while still achieving efficiency improvements in critical flux regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies partial grain orientation rather than complete grain orientation throughout the entire component. By implementing grain orientation only in specific regions where flux paths are well-defined, the patent achieves sufficient performance enhancement without the excessive complexity and cost of full-component grain orientation.

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If metal grains are aligned with flux paths, then magnetic flux flow is improved and losses are reduced, but the ability to accommodate varying flux directions is limited

Engineering Contradiction:

Improvemagnetic flux flowVSAvoidflux direction adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by providing grain-oriented metal portions in regions where flux paths are consistent and well-defined, while maintaining non-grain-oriented portions in regions where flux directions vary. This allows the oriented regions to provide reliable flux flow where needed, while the non-oriented regions provide adaptability to varying flux directions, thus resolving the contradiction between reliability and versatility.

Inventive Principle:

Principle #3Local quality

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 enhances the efficiency and performance of electromagnetic devices by aligning metal grains with flux paths, reducing reluctance and losses, and allowing for customized grain orientations in specific regions to match flux directions.

Implementation Method 1

a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path

Methodology Applied

Scientific EffectMagnetic flux conduction: Ferromagnetism

Implementation Method 2

additive manufacturing and post-processing techniques like laser or electron beam melting

Methodology Applied

Scientific EffectLaser or electron beam melting: Laser

Implementation Method 3

laser or electron beam melting

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 4

thermo-mechanical methodologies, to optimize grain orientation and crystallographic texture

Methodology Applied

Scientific EffectThermo-mechanical processing: Heat Treatment

Data Source

PatentUS11431208B2Electric component including custom metal grain orientation

Publication Date: 2022.08.30 HAMILTON SUNDSTRAND CORP

AI summary

An electrical device includes an electromagnetic component configured to generate a magnetic flux. The electromagnetic component includes a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path. The soft magnetically-conductive material includes at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux.