Economical Core Design for Electromagnetic Devices

Abstract

A magnetic core for an electromagnetic device is formed from alternating interleaved steel laminations. The core comprises a plurality of core elements comprising legs and yokes oriented substantially quadrature to the legs, such that abutting core elements are in substantially quadrature relation. A plurality of flux deflection zones are defined in regions where flux flows from one core element to an abutting core element. At least one of the layers has at least one core element composed of grain-oriented steel, and the remaining core elements are composed of non-grain-oriented steel, such that at least some flux deflection zones are composed of a substantial amount or substantially entirely of non-grain-oriented steel. Flux flowing in the direction of the grain orientation in the core element(s) composed of grain-oriented steel changes direction to flow through the abutting core element in the flux deflection zone composed of non-grain-oriented steel. This reduces the power losses in flux deflection zones of the core relative to cores formed entirely from grain-oriented steel, because the flux is never flowing perpendicular to the direction of the grains in the steel, while providing a design that is considerably less expensive than cores formed from non-grain-oriented steel with substantially the same level of power losses or lower.

Dependencies are inferred from the claim text.