Material with directional microstructure

Patent metadata

Field	Value
Publication number	US-10622848-B2
Application number	US-201715484486-A
Country	US
Kind code	B2
Filing date	Apr 11, 2017
Priority date	Apr 11, 2016
Publication date	Apr 14, 2020
Grant date	Apr 14, 2020

Abstract

A material comprises at least one layer of a plurality of domains, each domain being flattened in a first direction and elongated in a second direction normal to the first direction. The flattened and elongated domains define an anisotropic microstructure that facilitates a magnetic flux flow in the second direction.

First claim

What is claimed is:

1. A material, comprising:
at least two layers, each comprising a plurality of domains, each domain being flattened in a first direction and elongated in a second direction normal to the first direction;
wherein the domains of an upper layer of the at least two layers are deformed on undersurfaces thereof to correspond to upper surfaces of the domains of a lower layer of the at least two layers; and
wherein the flattened and elongated domains define an anisotropic microstructure that facilitates a magnetic flux flow in the second direction.

2. The material of claim 1 , wherein each domain comprises a core of electrically conductive material at least partially surrounded by a coating of electrically insulating material to form an insulating boundary on the core.

3. The material of claim 2 , wherein the core of electrically conductive material comprises an iron alloy, and wherein the coating of electrically insulating material comprises aluminum oxide.

4. The material of claim 1 , wherein the flattened and elongated domains exhibit an increased permeability in the second direction relative to a permeability in the first direction.

5. The material of claim 4 , wherein the flattened and elongated domains exhibit an increased electrical resistivity in the first direction relative to an electrical resistivity in the second direction.

6. The material of claim 1 , wherein each domain of at least one of the layers comprises electrically conductive material and each domain of at least one of the other layers comprises an electrically insulating material, wherein the at least one of the other layers insulates the at least one of the layers of electrically conductive material.

7. The material of claim 1 , wherein the at least one layer of a plurality of domains is curved to conduct magnetic flux in a non-linear direction.

8. The material of claim 1 , wherein domains of the upper layer are deposited on domains of the lower layer so as to overlap with the domains of the lower layer.

9. A stator core of a radial-field electric motor, the stator core comprising:
a yoke having a ring structure; and
tooth structures extending radially inward from an inner-facing surface of the yoke;
wherein the yoke comprises a material defined by at least two layers, each layer comprising a plurality of domains, the domains of each layer being flattened in a first direction and elongated in a second direction normal to the first direction;
wherein the domains of an upper layer of the at least two layers are deformed on undersurfaces thereof to correspond to upper surfaces of the domains of a lower layer of the at least two layers; and
wherein the flattened and elongated domains define an anisotropic microstructure that facilitates a magnetic flux flow in the second direction in the yoke.

10. The stator core of claim 9 , wherein the domains are deposited to define the anisotropic microstructure as a direction- and location-dependent microstructure.

11. The stator core of claim 9 , wherein the tooth structures comprise isotropic microstructures.

12. The stator core of claim 9 , wherein the anisotropic microstructure in the yoke is configured to facilitate circumferential magnetic flux flow in the yoke.

13. A stator winding core of a hybrid-field electric motor, the stator winding core comprising:
a yoke having a ring structure;
a plurality of teeth on an inner-facing surface of the yoke;
wherein the yoke and the teeth each comprise a material defined by at least two layers, each layer comprising a plurality of domains, the domains of each layer being flattened in a first direction and elongated in a second direction normal to the first direction;
wherein the domains of an upper layer of the at least two layers are deformed on undersurfaces thereof to correspond to upper surfaces of the domains of a lower layer of the at least two layers; and
wherein the flattened and elongated domains define an anisotropic microstructure that facilitates a magnetic flux flow in the second direction in one or more of the yoke and the teeth.

14. The stator winding core of claim 13 , wherein the magnetic flux flow in the teeth is bidirectional, radially inward, or radially outward.

15. The stator winding core of claim 13 , wherein the magnetic flux flow in the teeth is angled relative to a principal axis of the yoke.

16. The stator winding core of claim 13 , wherein the magnetic flux flow in one or more of the yoke and the teeth is omnidirectional.

17. The stator winding core of claim 13 , wherein a direction of the magnetic flux flow is varied between different regions of each of the teeth.

18. The stator winding core of claim 13 , wherein each domain comprises a core of electrically conductive material at least partially surrounded by a coating of electrically insulating material to form an insulating boundary on the core.

19. The stator winding core of claim 18 , wherein the core of electrically conductive material comprises an iron alloy, and wherein the coating of electrically insulating material comprises aluminum oxide.

20. The stator core of claim 13 , wherein the flattened and elongated domains exhibit an increased permeability in the second direction relative to a permeability in the first direction, and wherein the flattened and elongated domains exhibit an increased electrical resistivity in the first direction relative to an electrical resistivity in the second direction.

Assignees

• Persimmon Technologies Corp

Inventors

• Hosek Martin
• Krishnasamy Jayaraman

Classifications

• C22C2202/02

  Magnetic · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F5/106

  Tube or ring forms · CPC title

• H01F41/0206

  Manufacturing of magnetic cores by mechanical means (magnetic cores per se H01F27/24) · CPC title

• H02K1/02 Primary

  characterised by the magnetic material · CPC title