Magnetostrictive Element Lamination for Low-Cost Stable Power Output
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Solution Overview
Problem
Conventional magnetostrictive materials like FeGa, FeCo, and FeAl alloys are expensive and have limited formability, leading to high manufacturing costs and limited power generation performance in magnetostrictive power generation devices.
Innovation Solution
A magnetostrictive element using an electrical steel sheet with a stress control part formed of an elastic material, where the Young's modulus and sheet thickness of both materials satisfy specific relationships, allowing for uniform strain application and enhanced power generation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional magnetostrictive materials (FeGa, FeCo, FeAl alloys) are used to achieve large magnetostriction and high power generation output, then power generation performance is improved, but manufacturing cost increases and formability is limited
Solution Approach 1:
The patent uses a composite structure combining electrical steel sheet (magnetostrictive layer) with resin or metal backing layers. The electrical steel provides necessary magnetostriction at lower cost compared to FeGa/FeCo alloys, while the backing layers provide mechanical support and enable uniform strain application through the lamination structure, achieving cost-effective power generation performance
Solution Approach 2:
The patent changes the material parameter from expensive FeGa/FeCo/FeAl alloys to more economical electrical steel sheet, and adjusts the thickness parameters of the magnetostrictive layer and backing layers to optimize both cost and performance. By controlling the thickness ratio and material properties, the patent maintains adequate magnetostriction while reducing manufacturing cost
2Power
If conventional magnetostrictive materials are used to achieve large magnetostriction, then power generation output increases, but variations in power output increase
Solution Approach 1:
The laminated composite structure with electrical steel sheet and backing layers provides uniform strain distribution across the magnetostrictive element. This uniformity reduces variations in magnetic flux density changes during vibration, leading to more consistent electromotive force generation and reduced power output variations, thereby improving reliability
Solution Approach 2:
The patent applies different material properties to different layers: the electrical steel sheet provides magnetostriction with controlled local magnetic properties, while the resin or metal backing layers provide mechanical compliance and uniform stress distribution. This local differentiation of material functions reduces hotspots and non-uniformities that cause power variations
3Ease of manufacture
If electrical steel sheet is used as magnetostrictive material to reduce cost, then manufacturing cost decreases, but magnetic flux density change may be insufficient
Solution Approach 1:
The patent compensates for the lower magnetostriction of electrical steel by creating a composite lamination where the electrical steel sheet is bonded to resin or metal backing layers. This composite structure enhances the overall magnetic flux density change by combining the magnetostrictive effect with the mechanical compliance of the backing layers, achieving sufficient power generation output at lower cost
Solution Approach 2:
The patent optimizes the thickness parameters of the electrical steel sheet and backing layers to maximize magnetic flux density change. By adjusting these dimensional parameters and the material composition ratio, the patent achieves adequate magnetostriction performance from electrical steel without requiring expensive alternative materials
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 proposed solution reduces manufacturing costs while achieving power generation performance equivalent to or exceeding that of conventional materials, with improved magnetic flux density changes and reduced variations in power output.
Implementation Method 1
The reverse magnetostriction is a phenomenon in which the magnetization of the magnetostrictive material changes when strain is applied to the magnetostrictive material by vibration or the like
Implementation Method 2
an electromotive force is generated in the coil wound around the magnetostrictive element, in accordance with the law of electromagnetic induction
Data Source
AI summary
Task of the present invention is to provide a power-generating magnetostrictive element and a magnetostrictive power generation device equipped with the same, which are capable of achieving the same or a greater magnetostrictive power generation amount compared to conventional technology while employing materials lower in cost compared to conventional magnetostrictive materials. The task is achieved by providing a magnetostrictive element comprising a magnetostrictive part formed of an electromagnetic metal sheet. The present invention also provides a power-generating magnetostrictive element and a power-generating magnetostrictive element having high voltage with little variation. The task is achieved by providing a magnetostrictive element comprising a magnetostrictive part formed from a magnetostrictive material and a stress control part formed from an elastic material, the materials each having a Young's modulus and a sheet thickness simultaneously satisfying specific relationships.