Hybrid and electic vehicles magetic field and electro magnetic field interactice systems

• US 20110074231A1
• Filed: 09/02/2010
• Published: 03/31/2011
• Est. Priority Date: 09/25/2009
• Status: Abandoned Application

• Current Assignee: Soderberg Rod F
• Original Assignee: Soderberg Rod F
• Inventors: Soderberg, Rod. F.
• Application Number:
  US12/923,106
• Publication Number:
  US 20110074231A1
• Time in Patent Office: Days
• US Class Current: 310/44
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• CPC Class Codes: H01F 7/0221 Mounting means for PM, supporting, coating, encapsulating PM
• CPC Class Codes: H02K 1/02 characterised by the magnetic material
• CPC Class Codes: H02K 1/17 Stator cores with permanent magnets
• CPC Class Codes: H02K 23/04 having permanent magnet excitation
• CPC Class Codes: H02K 5/02 Casings or enclosures characterised by the material thereof
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y10T 428/12097 Nonparticulate component encloses particles

Abstract

A magnetic field interactive material being part of a machine component or mechanism utilizing magnetic or electro-magnetic field forces in said components operation and comprising specifically located magnetic particles incorporated into a non homogeneous amalgamation within the matrix or structural matrix of primarily a metal material differing from that of the magnetic particles therein forming an integrated component possessing magnetic field interactive capabilities, allowing such magnetic field interactive components to have a wide array of uses one of which is associated with Hybrid and Electric Vehicles.

Claims

1. A material, being part of a component, comprising specifically located concentrations of magnetic particles incorporated into at least one of;

a matrix of a different metal, a structural matrix of a different metal, a matrix of another type of magnetic particle, thereby creating a non homogeneous amalgamated material forming an integrated component possessing and sustaining magnetic field interactive capabilities, said material being defined as a distributed magnetic metal matrix composite material, and said integrated component being defined as a magnetic field interactive component.

2. The material of claim 1, being part of a component defined as a magnetic field interactive component wherein said component forms part of a mechanism, being a mechanical device, incorporated into but not restricted to;

an integrated magnetic multi-pole array, a hybrid vehicle, an electric vehicle, a car, a bus, a cycle, a truck, a train, an aircraft, an electric motor/generator, an electric pump, a magnetic torque transfer pump, a vehicle auxiliary drive motor, a fan, a magnetic torque transfer system, a magnetic gear box, a pseudo-direct drive motor/generator, a magnetic bearing, a magnetic castor, a magnetically supported shaft, an integrated wheel motor/generator system, a magnetic field levitated vehicle, an electric hand tool, an electric household appliance, a linear drive motor/actuator, a tubular linear drive motor/actuator, a wheel rim, a wheel hub, a rotor disk, a rotor and stator of an electric motor, a brake rotor disk, a drive shaft, a gearbox component, a fly wheel, a steering rack and pinion servo-system, wherein said mechanism possesses structural and architectural attributes associated with the mechanism while also possessing magnetic field interactive capabilities.

3. The material of claim 1 wherein said material forms a magnetic component of a magnetic field interactive mechanism such that the magnetic component exhibits a specifically located and aligned primary magnetic field force which is interacted upon by a secondary magnetic field force which reinforces the primary magnetic field force thereby increasing said magnetic components capacity to generate torque, power, and energy while eliminating demagnetization potential at the increased capacity of the magnetic component and also allowing flux weakening of the magnetic component by reducing the reinforcing effects of the secondary magnetic field force, wherein said secondary magnetic field force is created by, but not restricted to ;

a co-axial coil winding, a remote acting magnetic flux imposing co-axial flux on the primary magnetic field force, thereby creating a magnetic flux variable mechanism with demagnetizing protection and flux weakening ability resulting in a more efficient mechanism.

4. The material of claim 1 wherein said material is formed into a “

V”

formation in cross section, therein providing a basis on which a magnetic coil array is formed, said coil array being one of but not restricted to;

a stator drive coil, a rotor drive coil, a linear drive coil winding, a reinforcing coil associated with a magnetic material, wherein an array of “

V”

coil wound cores comprises the magnetic particles of claim 1 being at least one of but not restricted to;

a core material utilizing permanently magnetic particles reinforced with co-axial coils, a core material utilizing soft magnetic particles with co-axial coil windings, a core formed of non magnetic material in place of magnetic particles therein acting similarly to an air core while supporting a “

V”

coil formation, wherein the coil is;

wound externally around a core, formed into a core structural matrix, inserted into a co-axial hollow section within said core, whereby a magnetic flux and associated magnetic poles are created by;

permanently magnetic particles, electrical current flow within co-axially acting coils associated with a soft magnetic particle core, electrical current flow within coils associated with non magnetic core material which is utilized in place of magnetic particles, induced in electrically conductive particles by a changing interactive magnetic field, wherein said “

V”

cores are arranged so that a wide section of a “

V”

faces an air gap and like poles are in proximity to like poles and adjacent to an air gap creating reinforcing fields while a base of a “

V”

which is integrated into a component matrix forms a non like pole region of a back flux return path, therein eliminating a need for back iron.

5. The material of claim 1 comprising magnetic particles which give rise to magnetic field forces specifically aligned, located and concentrated within at least one of;

a component matrix, a component structural matrix, forming a non homogeneous amalgamation of magnetic particles which create a specific magnetic field array which forms an integrated magnetic multi-pole array being at least one of, but not restricted to;

a “

Diagonal V”

array, having a “

V”

shaped array wherein a wide section of the “

V”

faces an air gap and like poles are in proximity to like poles and adjacent to the air gap with pairs of like poles all facing the air gap therein creating a reinforcing magnetic field with non like poles joining at a base point of the “

V”

forming back face flux return paths which eliminate any necessity for back iron within a component matrix material into which the “

V”

base is amalgamated;

a “

Halbach”

array utilizing said integrated magnetic multi-pole array as was utilized with the “

Diagonal V”

array, whereby both the “

Diagonal V”

array and the “

Halbach”

array concentrate magnetic flux on an air gap face;

a like pole to like pole array created utilizing an integrated magnetic flux at like pole interfaces creating intense flux concentrations as is an advantage of the “

Diagonal V”

array however unlike the “

Diagonal V”

array this array does not concentrate flux on one side;

a conventional alternating north, south pole array easily created utilizing an integrated magnetic multi-pole array, wherein all magnetic field arrays hereby defined form a material with integrated magnetic particle concentrations specifically located within a metal matrix component said material being defined as a distributed magnetic metal matrix composite which forms an integrated component.

6. The material of claim 5 which is defined as a distributed magnetic metal matrix composite material wherein said material forms a magnetic field interactive component with an integrated multi-pole magnetic array being one of, but not restricted to;

a “

Diagonal V”

array, a “

Halbach”

array, wherein said integrated magnetic multi-pole array is incorporated into a specific component and provides a primary source of passive magnetic field flux for, but not restricted to;

a magnetic levitation vehicle, a magnetic bearing, a permanent magnet rotor of an electric machine, a multiple disk motor/generator, a flywheel mechanism with motor/generator capabilities, a component of a vehicle transmission assembly therein providing an addition motor/generator capability to said component, integrated into a component of a vehicle drive assembly including a wheel assembly, thereby enabling said component with an additional motor/generator capability, which is utilized as a powerful magnetic array integrated into a vehicle component such as;

a steering rack, therein performing a function of a tubular linear motor providing frictionless servo assistance to a steering rack, providing high strength magnetic fields incorporated into a vehicle wheel rim, therein creating a structurally integrated in-wheel motor/generator, utilized in place of a conventional disk brake, to allow the formation of a combined motor/generator and friction disk brake, said magnetic field interactive component possessing structural and architectural characteristics associated with a specific component while also sustaining magnetic field generating capabilities.

7. The material of claim 1 comprising specifically located concentrations of magnetic particles wherein said magnetic particles are at least one of;

permanently magnetic particles, soft magnetic particles, electrically conductive particles which become magnetically interactive under the influence of a varying magnetic field, piezoelectric particles which emit magnetic field forces as a result of an imposed force, combinations of said listed particles.

8. The material of claim 1 which can be utilized in a wide array of magnet field interactive components and mechanisms, one type of which, is a permanent magnet rotor synchronous electric motor/generator with coil wound salient stator poles which interact with a rotor of a type with, but not restricted to;

a solid cylindrical form, a hollow cylindrical form with metal spoke shaped material which is fibre reinforced for added structural integrity linking a peripheral region maintaining magnetic field flux with an inner axial support region wherein voids between the spoke shaped material save matrix material, reduces weight and eases magnetizing of the peripheral region, said rotor having a peripheral region comprised of a distributed magnetic metal matrix composite material which utilizes a rotor of alternating north, gap, south magnetic poles, aligned axially along a rotor peripheral surface length, which comprise arrays of magnetic particles, with adjoining flux return paths eliminating a need for back iron, incorporated into a non homogeneous amalgamation within a metal matrix of a different metal to that of the magnetic particles wherein an integrated magnetic multi-pole rotor is formed which possesses magnetic flux which interacts with electronically controlled salient coil wound stator core poles evenly disposed in an axial alignment within a motor casing with an air gap separating said stator core poles from a rotor periphery wherein stator cores are formed from soft magnetic particles of a different metal to that of the casing matrix, which are integrated into the motor casing so as to form a distributed magnetic metal matrix composite with magnetic particles blending into the motor casing matrix and forming a continuity of flux paths between the stator core poles therein eliminating a need for back iron, said salient coil wound stator poles being, but not restricted to;

unitary protruding blocks, “

V”

cores with “

V”

coils which create a flux return path within a “

V”

base which amalgamates with matrix metal forming a casing therein further reducing back face flux path over that of a block shaped stator core pole which requires a flux path linking pole blocks, said “

V”

coil and associated “

V”

core additionally improves casing structural integrity, said “

V”

coils also producing highly concentrated flux densities, wherein said motor/generator utilize distributed magnetic metal matrix composite material in a rotor and a combined stator and motor casing.

9. The material of claim 1, forming part of a magnetic field interactive component associated with passive and actively controlled magnetically levitated vehicles having operating principles which have similarity to passive and actively controlled magnetic bearings wherein said magnetically levitated vehicles utilize a distributed magnetic metal matrix composite to form an integrated magnetic multi-pole array of permanently magnetic particles incorporated into a metal matrix of a different metal to that of the magnetic particles in place of a permanent magnet segment array wherein said integrated magnetic multi-pole array is arranged in;

a “

Diagonal V”

array, a “

Halbach”

array, a suitable alternative array, whereby at least one method of levitation is utilized this being one of two alternatives;

a passive system of moving magnetic field arrays which interact with a track of disposed conductors of at least one of

shorted coils, stacks of insulated conductive laminates, a suitable alternative inductive material, to create opposing inductive forces in said track which levitate a vehicle, a second alternative being;

an active system of magnetic field arrays which are attracted to a magnetically interactive component, being but not restricted to;

a similar magnetic array to that of the passive system with non like poles adjacent to one another across an air gap, a soft magnetic metal in proximity across an air gap wherein at least one magnetic array has co-axially acting electronically controlled electro-magnetic flux adjusting overall field strength while monitoring relative location between interactive magnetic components, thereby maintaining a stable air gap width and allowing stable levitation of a vehicle.

10. The material of claim 1 comprising magnetic particles which give rise to magnetic field forces incorporated within a structural matrix of a passive magnetic bearing which forms an axial support shaft of a combined motor and generator mechanism, said axial support shaft being at least one of;

an integrated part of the passive magnetic bearing, a support for a separate attachment of an integrated multi-pole array forming an inner section of a passive magnetic bearing, wherein an opposing magnetic field results from one of two alternatives;

a first alternative being a cylinder of disposed conductors rigidly mounted around a periphery of said passive magnetic bearing of the axial support shaft, composed of but not restricted to;

shorted conductive coils, insulated conductive laminates in which an opposing interactive magnetic field is induced by axially aligned flux poles of said passive magnetic bearing associated with the axial support shaft which includes an attachment to said axial support shaft;

a second alternative being an integrated magnetic multi-pole array rigidly contained in proximity to an axial support shaft comprising a magnetic array wherein the passive magnetic bearing associated with the axial support shaft has like poles of a magnetic array opposing a rigidly contained integrated magnetic multi-pole array aligned across an air gap so that like poles of magnetic arrays are opposite one another in a repulsion mode, wherein said magnetic array is;

a “

Diagonal V”

array, a “

Halbach”

array, a suitable alternative array with a capacity to provide radial and axial support to a shaft as a result of;

forming said passive bearing with a conical formation which applies magnetic flux forces with axial and radial components and results in axial and radial shaft support which can be enhanced in terms of shaft stability by combining induced repulsion effects with those of purely magnetic repulsion effects.

11. A magnetic field interactive mechanism forming a mechanical device comprising magnetic particles which give rise to magnetic field forces, wherein said magnetic particles are incorporated in specifically located concentrations, within a structural matrix of a different material comprising at least one of;

a metal matrix, a non metal matrix, a magnetic particle matrix of another type of magnetic particle, wherein incorporation of said magnetic particles forms a non homogeneous amalgamated material comprising assimilated concentrations of magnetic particles incorporated into said structural matrix to form an integrated structural component possessing magnetic field interactive capabilities which is thereby defined as a “

multifunctional”

mechanism.

12. The magnetic field interactive mechanism of claim 11 comprising magnetic particles which give rise to magnetic field forces incorporated in specifically located concentrations within a structural matrix of a disk of a different material to that of the magnetic particles creating a mechanism of axially supported rotational disks which as example, comprises two disks, said disks including a space between disks which locates a suitable disk shaped drive coil with air gaps between interior faces and the drive coil wherein said disks incorporate integrated magnetic multi-pole arrays, being at least one of;

a “

Diagonal V”

array, a “

Halbach”

array, a suitable alternative array, wherein high intensity magnetic flux fields are created on inner disk surfaces adjacent to the drive coil creating an interaction between drive coil flux and disk magnetic flux which give rise to rotational torque forces, said disk and drive coil mechanism forming part of, but not restricted to;

a combined motor and generator which in this example replaces a friction brake disk mounted co-axially within a wheel assembly, said disk and coil assembly additionally including an integral friction brake disk whereby said disk and coil assembly provides the wheel assembly with integral capabilities of a motor, a generator, a friction brake, and a regenerative brake.

13. The magnetic field interactive mechanism of claim 11 comprising a non homogeneous material incorporating concentrations of magnetic particles wherein a wide array of magnetic particle concentration distributions can be utilized;

varying in an axial direction, varying in a radial direction, varying in a circumferential direction, thus as example, in an array magnetic particles form a uniform surface concentration around a cylindrical rotors surface region, there being a variation in a radial direction from a highly concentrated magnetic particle distribution in the rotors surface region deminishing to primarily a matrix material within inner regions of a rotor, particles being incorporated and amalgamated into a matrix material so as to form a structurally and architecturally integrated component with a peripheral surface of uniform concentrations of magnetic particles which in an array of this example forms a multi-pole magnetic array over said rotors surface region.

14. The magnetic field interactive mechanism of claim 11 comprising magnetic particles which give rise to magnetic field forces, wherein said magnetic particles are incorporated in specifically located concentrations within an electric motor casings structural matrix, said casing comprising permanently magnetic particles incorporated within said casing of;

metallic non magnetic material, non metallic material, particles of a different type of magnetic particle, a suitable material additionally reinforced with incorporated fibres, wherein said permanently magnetic particles form a magnetic array being at least one of;

a “

Diagonal V”

array, a “

Halbach”

array, a suitable alternative array, forming a non homogeneous amalgamation of permanently magnetic particles incorporated and assimilated into another material matrix to form an integrated structural casing of, in this example an electric motor utilizing a coil wound rotor with at least one of;

commutator power supply to rotor coils, slip rings plus electronic control of power delivery to rotor coils, a suitable alternative means of power supply to rotor coils, wherein a magnetic flux associated with said coil wound rotor interacts with permanently magnetic particle arrays which are;

non flux reinforced permanently magnetic particle arrays, reinforced with co-axially applied magnetic flux to eliminate a risk of demagnetization of permanently magnetic particles while allowing increased motor torque and field weakening capabilities due to reducing coaxially applied magnetic flux at high motor speeds thereby reducing back emf in the coil wound rotor, wherein a highly efficient motor is created.

15. The magnetic field interactive mechanism of claim 11 comprising magnetic particles which give rise to magnetic field forces incorporated in specifically located concentrations within a structural matrix of a different material to that of the magnetic particles creating a vehicle associated mechanism being at least one of;

a wheel rim, an addition to a wheel rim, a wheel hub, a suitable rotational component, utilizing integrated magnetic multi-pole arrays comprising at least one of;

a “

Diagonal V”

array, a “

Halbach”

array, a suitable alternative array, wherein high intensity magnetic fields are created in a surface of said vehicle associated mechanism adjacent to a drive coil wherein an interaction between drive coil flux and the integrated magnetic multi-pole arrays give rise to rotational torque forces acting on the vehicle associated mechanism creating a combined motor and generator thereby defining said vehicle associated mechanism as a multifunctional mechanism possessing architectural and structural load bearing functions associated with, as example a wheel rim, while integrating specific magnetic flux arrays thereby creating an in wheel combined motor and generator with regenerative braking capabilities.

16. The magnetic field interactive mechanism of claim 11 comprising magnetic particles which give rise to magnetic field forces incorporated in specifically located concentrations within a structural matrix of a different material to that of the magnetic particles creating a vehicle associated steering rack servo-assistance mechanism utilizing integrated magnetic multi-pole arrays comprising at least one of;

a “

Diagonal V”

array, a “

Halbach”

array, a suitable alternative array, wherein high intensity magnetic fields are created within a steering rack gear rod incorporating said integrated magnetic multi-pole arrays in proximity to a drive coil incorporated within a casing enveloping said steering rack gear rod, wherein an interaction between drive coil flux and the integrated magnetic multi-pole arrays of the steering rack gear rod give rise to a linear drive force acting on said steering rack gear rod, wherein said vehicle associated steering rack servo-assistance mechanism provides functions associated with a steering rack while comprising magnetic particles in integrated magnetic multi-pole arrays within a steering rack structural matrix to provide servo-assistance to a steering rack.

17. A process for manufacturing a distributed magnetic metal matrix composite material utilizing metallurgical techniques and technology wherein specifically located concentrations of magnetic particles are bound in a non homogeneous amalgamation within;

a metal matrix of a different metal to that of the magnetic particles, a metal structural matrix of a different metal to that of the magnetic particles, a different magnetic particle forming a matrix, a combination of two or more metal matrix types, thereby forming an integrated material with magnetic field interactive capabilities.

18. The process for manufacturing a distributed magnetic metal matrix composite material of claim 17 wherein said specifically located concentrations of magnetic particles comprises at least one of;

loose unbound magnetic particles, magnetic particles bound into a preform, a blend of more than one type of magnetic particles, a blend of magnetic particles and metal matrix particles of a different metal, a blend of magnetic particles and a flowable fluid form of metal matrix material of a different metal to that of the magnetic particles, wherein said magnetic particles are specifically distributed and aligned to form concentrations of specifically located magnetic particles which form localized arrays of magnetic particles within at least;

a matrix of a different metal, a structural matrix of a different metal, a matrix of different magnetic particles thereby forming a non homogeneous material with magnetic interactive capabilities.

19. The process for manufacturing a distributed magnetic metal matrix composite material of claim 17 wherein a mold consists of, but is not restricted to;

upper and lower former plates which incorporate specific magnetic flux arrays, associated mold sides, said mold containing a specific quantity of at least one of;

a blend of magnetic particles and non magnetic metallic matrix particles, a blend of magnetic particles and metallic matrix particles of a differing magnetic field interactive capacity to that of the magnetic particles, a blend of magnetic particles and different magnetic particles wherein said different magnetic particles also possess different magnetic field interactive capacity, a blend of magnetic particles and a flowable fluid form of metal matrix material of a different type of metal to that of the magnetic particles and possessing differing magnetic field interactive capacity to that of the magnetic particles, wherein prior to said mold contents sustaining heat and pressure, mold applied magnetic field forces act on the blend of magnetic particles and matrix metal whereby said magnetic field forces, which mirror magnetic arrays required in a finished component, concentrate magnetic particles in specific locations and arrangements and align anisotropic magnetic particles, said magnetic field forces being assisted in separating, concentrating and aligning by, but not restricted to;

creation of a fluidized particle bed by gaseous intrusion, vibration of the mold utilizing;

mechanical, magnetic, acoustic or suitable alternative means, thereby creating a distributed magnetic metal matrix composite component.

20. The process of manufacturing a distributed metal matrix composite material of claim 19 wherein an alternative method to magnetic field concentration of magnetic particles is desired;

when magnetic particles and a matrix metal have similar magnetic field interactive capacity;

when complex arrays must be formed, whereby said concentrations of specifically located magnetic particles is achieved by forming magnetic particle preforms, said preforms being premagnetized in specific magnetic flux arrays prior to installation into the mold, said preforms alternatively being magnetized upon installation into the mold by said mold applied magnetic field forces, wherein mold flux also assists in maintaining said preform in position, said mold containing a specific amount of matrix metal in addition to the preforms, said matrix metal being in a;

particle form, a flowable molten liquid form, a plastic form, a fluidized particle form, wherein contents of said mold are subjected to heat and pressure which fuses and sinters magnetic particles and forces matrix material into porous regions of the preform, a process which can be assisted by special pre-coating on particles, thereby creating an integrated multi-pole array within a component.