Magnetic Device Fabrication via Selective Laser Sintering
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Solution Overview
Problem
Existing methods for fabricating magnetic devices face limitations in reducing eddy current loss and improving magnetic permeability, especially in high-speed motor applications, due to challenges in shaping magnetic materials and heat dissipation, leading to reduced service life and potential damage from excessive heat.
Innovation Solution
A fabrication method involving selective energy beam irradiation of magnetic materials in a reacting gas environment to form solidified layers with barrier layers, allowing for the creation of small unit combinations and 3D structures that reduce eddy current loss and enhance magnetic permeability, using techniques like selective laser sintering and additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the thickness of silicon steel sheets is decreased to reduce eddy current loss, then eddy current loss decreases, but manufacturing complexity and cost increase
Solution Approach 1:
The magnetic core is segmented into multiple thin silicon steel sheets (e.g., 0.03-0.05mm thickness) stacked in layers. Each sheet is further divided into magnetic units with barrier layers at interfaces, creating a segmented structure that limits eddy current paths while maintaining manufacturability through modular assembly.
Solution Approach 2:
Barrier layers (non-magnetic or high-resistance layers) are introduced as intermediary elements between adjacent magnetic material layers. These barrier layers have thickness of 1-10 micrometers and provide electrical isolation to reduce eddy current loss without requiring extreme thinning of the magnetic sheets themselves.
2Loss of energy
If SMC material is compressed to form polymer interface layers for reducing eddy current loss, then eddy current loss decreases, but magnetic permeability and heat resistance deteriorate
Solution Approach 1:
The barrier layer parameters are optimized: thickness reduced to 1-10 micrometers (much thinner than polymer layers), material composition changed to non-magnetic or high-resistance materials with appropriate electrical properties, and positioning precisely controlled at interfaces between magnetic units to minimize impact on magnetic performance while maintaining heat resistance.
Solution Approach 2:
The magnetic device uses composite structure combining magnetic material layers with thin barrier layers. The barrier layers are made of non-magnetic or high-resistance materials that are compatible with the magnetic material, creating a composite structure that reduces eddy current loss while preserving magnetic permeability and heat resistance.
3Reliability
If magnetic material is shaped into complex 3D structures for high-speed motor applications, then performance improves, but manufacturing difficulty increases
Solution Approach 1:
The complex 3D magnetic structure is segmented into multiple thin layers of silicon steel sheets, each layer containing magnetic units that can be independently manufactured and then assembled. This segmentation allows use of conventional sheet manufacturing processes while achieving complex overall geometries through stacking and arrangement of layers.
Solution Approach 2:
Complex 3D magnetic structures are achieved by stacking thin 2D silicon steel sheets in multiple layers, utilizing the third dimension (height/depth) to create complex geometries. This approach maintains ease of manufacturing in the plane of each sheet while achieving 3D complexity through layer stacking.
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
The method effectively decreases eddy current loss and heating, improves magnetic permeability, and enables the production of customized, high-performance magnetic devices suitable for miniaturization and high-speed applications, overcoming the limitations of conventional manufacturing processes.
Implementation Method 1
a portion of the magnetic material is selectively irradiated by using an energy beam, and a reacting gas is introduced simultaneously, such that during a process that the energy beam melts and solidifies the magnetic material
Implementation Method 2
the portion of the magnetic material being irradiated is melted and solidified to form a solidified layer, where an outer layer of the solidified layer reacts with the reacting gas to form a barrier layer on a surface of the solidified layer
Implementation Method 3
When the magnetic material is subjected to an electromagnetic field, the electromagnetic field is produced in internal thereof to generate an induced current, which is referred to as the eddy current
Implementation Method 4
The eddy current may produce a large amount of heat to decrease a service life of a magnetic device as well as an external device
Data Source
AI summary
A fabrication method of magnetic device is provided. A magnetic material is provided. A portion of the magnetic material is selectively irradiated by an energy beam, and reactive gas is introduced simultaneously. The magnetic material being irradiated is melted and solidified to form a solidified layer. An outer layer of the solidified layer reacts with the reactive gas to form a barrier layer, so as to form a magnetic unit including the solidified layer and the barrier layer. It is determined whether the manufacturing process of the same layer is finished, if not, the energy beam is moved to the other portion of the magnetic material. The above step is repeated to overlap multiple magnetic units to form a magnetic layer. If yes, the flow returns to the 1st step to provide another magnetic material to the magnetic layer. The above steps are repeated to form a 3D magnetic device.