Magnetics Business & Technology - May/June 2022 - 32

PRODUCT NEWS
Sumitomo Electric into Mass Production of Powder Magnetic Cores for Axial Gap Motors
The powder magnetic core is formed by die-pressing soft magnetic
iron powder into a three-dimensional shape. Compared to
magnetic cores made of electrical steel sheets used in conventional
radial gap motors, it has great flexibility in terms of shape
design and superior high-frequency characteristics, says SEI.
" When using a powder magnetic core for a motor, it is usually
required to provide an additional component to ensure the dielectric
strength between the magnetic core and the copper winding.
However, our unique insulation coating technology has made it
possible to wind copper wire directly around the powder magnetic
core and thereby reduce costs for additional components
and assembly. This feature has also made it possible to expand
the winding space, which contributes to the development of more
compact and efficient motors. "
Sumitomo Electric Industries, Ltd. has developed a powder
magnetic core for the thin, axial gap motors that are becoming
increasingly popular with electric vehicle manufacturers for their
high performance, lighter weight and streamlined profile. The
company is now into mass production and delivery of the product,
also using a newly developed insulation coating technology
that enhances performance.
With recent growing demand for light and high-performance
motors, axial gap motors, also known as axial flux motors, are
attracting more attention due to their light weight, low thickness
yet high power density. The attributes have been achieved
by adapting completely different structure from conventional
radial gap motors. But to produce axial gap motors, high-quality
magnetic cores that suit their three-dimensional magnetic circuits
are critical, notes the company. " By utilizing our unique powder
metallurgy technology, we have developed a powder magnetic
core that helps to realize high-performance axial gap motors. "
The new insulation coating technology is designed to ensure
the dielectric strength between the powder magnetic core and
the copper winding. Now, says SEI, it will continue to develop
the market for powder magnetic cores for axial gap motors and
contribute to the development of higher performance axial gap
motors and equipment. It is providing design assistance for
three-dimensional electromagnetic field analysis based on motor
specifications provided by customers.
The image at left shows the new mass-produced insulationcoated
powder magnetic core and, at right, is a prototype. In the
accompanying table, SEI summarizes how electromagnetic field
analysis demonstrates that lighter weight and lower thickness
can be achieved by its new core with performance kept at the
same level as a conventional radial gap motor.
Based in Osaka, Japan, SEI has a pioneering history in magnetic
materials and technology. It is also a major manufacturer of magnet
wire and magnetic components.
See www.global-sei.com.
32 Magnetics Business & Technology * May/June 2022
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