Single-Piece Electromagnetic Pump Stator Cores With Slotted Teeth
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electromagnetic device stators require multiple discreet parts for insulation, leading to increased fabrication costs, complexity, and the need for additional joining structures that do not contribute to the magnetic field, limiting shaping and efficiency.
Innovation Solution
Magnetic cores with integrated teeth extensions formed by radial slots and a solid section, eliminating the need for separate joining structures, allowing for a single-piece, densely packed, and efficiently shaped stators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple discreet lamination sections are joined together to form stator cores, then insulation between magnetic elements is achieved, but fabrication cost and device complexity increase due to required joining structures
Solution Approach 1:
The patent merges the insulation function directly into the magnetic element structure by forming teeth extensions that integrate both magnetic functionality and insulation separation. This eliminates the need for separate joining structures, reducing device complexity while maintaining the insulation requirement between adjacent magnetic elements.
Solution Approach 2:
The teeth extensions serve multiple functions simultaneously: they provide magnetic field concentration, create insulation gaps between adjacent magnetic elements, and eliminate the need for separate joining structures. This multi-functionality reduces the overall number of components and simplifies the stator core assembly.
2Strength
If multiple discreet lamination sections are joined together with tie rods and end pieces, then structural integrity is achieved, but fabrication cost increases due to additional parts and assembly steps
Solution Approach 1:
The patent combines the structural support function with the magnetic element itself by using the teeth extensions to provide both magnetic functionality and structural separation. This eliminates the need for separate tie rods and end pieces, reducing the number of parts and assembly steps while maintaining structural integrity through the integrated design.
Solution Approach 2:
The patent extracts the joining structures (tie rods, end pieces) from the stator core assembly by integrating their functional equivalents directly into the magnetic elements through teeth extensions. This reduces the bill of materials and simplifies manufacturing while preserving the necessary structural separation and support.
3Reliability
If gaps are made numerous and small to produce finely separated extensions, then magnetic field efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent performs preliminary action by forming all gaps and teeth extensions in a single machining or molding operation on the solid magnetic material, rather than requiring subsequent assembly of multiple precision components. This preliminary formation of gaps ensures uniform spacing and dimensions while maintaining manufacturing feasibility.
Solution Approach 2:
The patent changes the manufacturing approach from assembling pre-made components with tight tolerances to forming the entire structure including gaps in a single operation. This parameter change in the manufacturing process allows for numerous small gaps to be created with consistent spacing without requiring extremely high manufacturing precision on individual components.
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 reduces fabrication costs and enhances magnetic field efficiency by up to 15-40% while enabling more complex and customized shapes without additional support structures.
Implementation Method 1
Each sheet 15 may be coated with insulation or have insulation filled between adjacent sheets 15. Multiple sheets 15, potentially fifteen, twenty, or more, are aligned and joined by tie rod 16 passing through sheets 15 and holding them as a single lamination section 10.
Implementation Method 2
As current is run through induction coils passing in a circular direction within stator cores 1 and 2, resultant magnetic fields in the ferromagnetic portions of the lamination sections 10 drive the fluid in channel 22 in an axial direction due to perpendicular electrical fields or current.
Data Source
AI summary
Systems and methods use bodies with multiple teeth that follow a magnetic field in the body. The teeth have adjacent gaps while the body remains a continuous rigid structure. The gaps may be any shape or size formed by removal from the parent body while preserving a continuous joining portion of the body. Cutting with electrical discharge wires or lasers may be used for the gaps. The body may take on any shape or size, including electromagnetic pump stator configurations. Recesses, including ledges, passages, toughs, bores, rounds, or flat faces may be formed with the gaps. Adjacent recesses between multiple bodies may form other functional passages, such as an angular or perimeter passage for driving coils in an electromagnetic pump. Insulators may be placed into the gaps. Example systems and methods require fewer additional joining or supporting structures due to the teeth already being connected from fabrication.