Hybrid stator core component design for axial flux motor
AssigneeGM Global Technology Operations LLC
InventorsJian Yao, Mingyuan Zhang, Chengwu Duan, Yusheng Zou
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Abstract
The present disclosure provides hybrid stator core components for an axial flux motor stator and methods for making the same. The hybrid stator core component includes a molded soft magnetic composite material and a laminated component. In one variation, a laminated insert comprising a plurality of insulated layers is non-releasably seated within a molded soft magnetic composite material. In another variation, a hybrid stator core component has a molded soft magnetic composite core and a laminated shell comprising a plurality of layers disposed around at least a portion of the molded soft magnetic composite core.
Claims20
A hybrid stator core component defining a magnetizable pole of a stator for an axial flux motor, the hybrid stator core component comprising:
- a bottom defining an inner circumferential surface and a top defining an outer circumferential surface;
- a first side defining a first recessed region and an opposite second side defining a second recessed region, the first side and the second side each extending in a radial direction between the bottom and the top;
- a laminated insert disposed in a central region between the bottom and the top and between the first side and the second side, the laminated insert comprising a plurality of insulated layers comprising a ferromagnetic material;
- and
- a molded soft magnetic composite material disposed around at least a portion of a perimeter of the laminated insert, wherein the laminated insert is non-releasably seated within the molded soft magnetic composite,
- wherein the first recessed region and the second recessed region are configured to receive a conductive wire winding that wraps around at least a portion of the perimeter of the laminated insert, and
- wherein the first recessed region and the second recessed region are defined by the molded soft magnetic composite material.
A hybrid stator core component defining a magnetizable pole of a stator for an axial flux motor, the hybrid stator core component comprising:
- a bottom defining an inner circumferential surface and a top defining an outer circumferential surface;
- a first side and an opposite second side, the first side and the second side each extending in a radial direction between the bottom and the top;
- a molded soft magnetic composite core disposed in a central region between the bottom and the top and between the first side and the second side;
- and
- a laminated shell comprising a plurality of layers comprising a ferromagnetic material, the laminated shell disposed around at least a portion of the molded soft magnetic composite core,
- wherein the laminated shell defines at least a portion of the inner circumferential surface, the outer circumferential surface, the first side, and the opposite second side.
A method of making a hybrid stator core component for an axial flux motor stator, the method comprising:
- disposing a laminated insert comprising a plurality of insulated layers comprising a ferromagnetic material in a mold having a predetermined shape corresponding to the hybrid stator core component, wherein the predetermined shape of the hybrid stator core component includes a bottom defining an inner circumferential surface, a top defining an outer circumferential surface, a first side defining a first recessed region, and an opposite second side defining a second recessed region, the first side and the second side each extending between the bottom and the top;
- and
- introducing a precursor of a soft magnetic composite material comprising a plurality of magnetic particles each having an insulating coating and applying pressure to mold a soft magnetic composite material around a portion of a perimeter of the laminated insert, wherein the laminated insert is non-releasably seated within the molded soft magnetic composite material such that the laminated insert is disposed in a central region of the hybrid stator core component between the bottom and the top and between the first side and the second side,
- wherein the first recessed region and the second recessed region are configured to receive a conductive wire winding that wraps around at least a portion of the perimeter of the laminated insert, and
- wherein the first recessed region and the second recessed region are defined by the molded soft magnetic composite material.
Dependencies are inferred from the claim text.