Magnetic Composite PCB Stators for Low-Loss Axial Flux Motors
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Solution Overview
Problem
Conventional planar printed circuit board stators in axial flux machines lack the benefits of soft magnetic materials, leading to inefficiencies and increased losses due to the use of non-magnetic substrates and laminated steel constructions, which result in tooling costs, winding limitations, and thermal concerns.
Innovation Solution
Incorporating soft magnetic materials into the substrate of printed circuit board stators, either by replacing the fiberglass substrate with ceramic insulators or integrating powdered soft magnetic materials with epoxy fillers to form a magnetic composite material within the interstitial gaps of conductive traces, thereby enhancing the magnetic properties and reducing losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional non-magnetic substrates (fiberglass, epoxy) are used in printed circuit board stators, then manufacturing simplicity and ease of fabrication are maintained, but magnetic performance is insufficient leading to increased losses and reduced efficiency
Solution Approach 1:
The patent applies composite materials by combining non-magnetic substrate materials (fiberglass, epoxy) with soft magnetic particles (ferrite, iron powder, or amorphous metal powder) to create a hybrid composite substrate. This composite structure provides both the mechanical support and electrical insulation properties of the non-magnetic substrate and the magnetic flux conduction properties of the soft magnetic particles, thereby reducing magnetic losses while maintaining ease of manufacturing through existing PCB fabrication processes.
2Productivity
If soft magnetic materials are integrated into the substrate, then magnetic performance and efficiency are improved, but manufacturing complexity increases due to additional materials and processes
Solution Approach 1:
The patent merges the functions of the substrate (mechanical support and electrical insulation) with the function of the magnetic core (flux conduction) by integrating soft magnetic particles directly into the substrate material. This consolidation eliminates the need for separate magnetic core assemblies and windings, simplifying the overall device structure while enhancing torque and voltage production through improved magnetic flux utilization.
3Temperature
If conventional air-core or non-magnetic substrate designs are used, then thermal management is simplified, but thermal performance deteriorates due to increased losses and reduced heat dissipation efficiency
Solution Approach 1:
The patent uses composite materials with soft magnetic particles embedded in the substrate to simultaneously address thermal performance and energy losses. The soft magnetic particles reduce eddy current losses and improve magnetic flux conduction, thereby reducing energy waste. Additionally, certain soft magnetic materials have good thermal conductivity, which enhances heat dissipation from the stator windings, improving overall thermal management while reducing energy losses.
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 integration of soft magnetic materials improves the performance of axial flux machines by increasing torque and voltage production, reducing losses, and allowing for thinner, more efficient stator designs with reduced magnet usage and improved thermal performance.
Implementation Method 1
at least the first portion comprises a soft magnetic material
Implementation Method 2
conductive traces supported by the dielectric substrate, the conductive traces forming windings for a least one pole of the planar armature
Data Source
AI summary
A dielectric substrate may support conductive traces that form windings for a least one pole of a planar armature of an axial flux machine. At least a portion of the dielectric substrate, which is adapted to be positioned within an annular active area of the axial flux machine, may include a soft magnetic material. Such a planar armature may be produced, for example, by forming the conductive traces on the dielectric substrate, and filling interstitial gaps between the conductive traces with at least one epoxy material in which the soft magnetic material is embedded.