Motor Stator Core with Amorphous Binding Parts

Solution Overview

Problem

Conventional motors using amorphous soft magnetic material cores suffer from low saturated magnetization, leading to reduced motor torque and mechanical strength, which deteriorates when the material is crystallized to improve magnetization, resulting in damage during manufacturing and operation due to stress concentration at the binding parts.

Innovation Solution

A motor design incorporating a stator core with a lamination of sheet members where the binding parts are made of amorphous soft magnetic material for mechanical strength and the magnetic path parts are made of nanocrystal soft magnetic material for higher saturated magnetization, maintaining mechanical strength while enhancing output characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the amorphous soft magnetic material is heated for crystallization to increase saturated magnetization, then the saturated magnetization of the core is improved, but the mechanical strength of the core deteriorates

Engineering Contradiction:

Improvesaturated magnetizationVSAvoidmechanical strength

Core Design Contradiction:

PowerVSStrength

Solution Approach 1:

The patent applies local quality by creating different material structures in different regions of the sheet member. The binding part maintains amorphous structure for high mechanical strength, while the magnetic path part is crystallized to nanocrystal structure for high saturated magnetization. This regional differentiation resolves the contradiction between mechanical strength and magnetic performance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates a composite material structure within the sheet member, combining amorphous and nanocrystal phases in specific regions. The amorphous binding part provides mechanical strength while the nanocrystal magnetic path part provides high magnetization, achieving a composite effect that resolves the contradiction.

Inventive Principle:

Principle #40Composite materials

2Power

If the binding part is made of nanocrystal soft magnetic material to improve magnetic performance, then the saturated magnetization is improved, but the mechanical strength and resistance to stress concentration deteriorate

Engineering Contradiction:

Improvesaturated magnetizationVSAvoidresistance to stress concentration

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent applies local quality by creating different material structures in different regions of the sheet member. The binding part maintains amorphous structure for high mechanical strength, while the magnetic path part is crystallized to nanocrystal structure for high saturated magnetization. This regional differentiation resolves the contradiction between mechanical strength and magnetic performance.

Inventive Principle:

Principle #3Local quality

3Strength

If the sheet members are stacked to form a lamination for the stator core, then the mechanical strength is improved, but the binding part becomes receptive to stress and may breakage during manufacturing and operation

Engineering Contradiction:

Improvemechanical strengthVSAvoidresistance to breakage at binding part

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies local quality by creating different material structures in different regions of the sheet member. The binding part maintains amorphous structure for high mechanical strength, while the magnetic path part is crystallized to nanocrystal structure for high saturated magnetization. This regional differentiation resolves the contradiction between mechanical strength and magnetic performance.

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

The solution effectively improves the motor's output characteristics while maintaining the mechanical strength of the stator core, preventing damage from stress concentration and reducing iron loss, thus enhancing the motor's performance and manufacturing stability.

Implementation Method 1

The binding part of the present disclosure is made of an amorphous soft magnetic material that has a higher mechanical strength than that of a nanocrystal soft magnetic material

Methodology Applied

Scientific EffectAmorphous structure:

Implementation Method 2

The second part of the present disclosure is made of a nanocrystal soft magnetic material having higher saturated magnetization than that of an amorphous soft magnetic material

Methodology Applied

Scientific EffectNanocrystal structure:

Implementation Method 3

The stator core includes a lamination of a plurality of sheet members made of a soft magnetic material

Methodology Applied

Scientific EffectLamination: Lamination

Data Source

PatentUS11557431B2Motor

Publication Date: 2023.01.17 TOYOTA JIDOSHA KK

AI summary

Provided is a motor capable of having an improved output while keeping the mechanical strength of the stator core. A motor includes: a stator including a stator core including an annular yoke having an outer part and an inner part and teeth extending inwardly from the inner part of the yoke, and a coil wound around the teeth; and a rotor rotatably disposed inside of the stator. The stator core includes the lamination of sheet members made of a soft magnetic material. Each sheet member has a binding part to bind the sheet members in the lamination at a first part corresponding to the outer part of the yoke. At least the binding part of the first part is made of an amorphous soft magnetic material. The sheet member has a second part other than the first part, and the second part is made of a nanocrystal soft magnetic material.