Development Of Soft Magnetic Composites Core For Axial Flux Motor Using Ultra-thin, High-withstand-voltage Insulation Coating Technology

As moving vehicles become more electric and home appliances and industrial equipment become more efficient, there is a growing need for smaller, lighter, and more efficient motors. Compared to the currently popular radial flux motor, axial flux motor (AFM) is a thinner motor that can provide high torque, and is attracting attention as one of the motors that meet the need. AFM requires a magnetic core that is compatible with AFM’s three-dimensional magnetic circuit, and it is preferable to use soft magnetic composites (SMC) that are magnetically isotropic and have high design flexibility in shape. So, to further improve motor performance, authors have developed SMC core with insulation coating that has high withstand voltage despite its thin thickness of several tens of micrometers. By applying this developed core for AFM, we have confirmed improvements in the space factor and heat dissipation of the coil, which we report in this paper.