Vehicle Traction Electric Machines Enabled by Novel Composite Magnetic Powder Material and Electrophoretic Deposition Insulation Material
The Ohio State University team will transform the design and manufacturing processes of electric machines for electrified vehicles (EVs) through innovative magnetic and insulation materials. First, the team will develop a novel composite magnetic powder material with high electrical resistivity, a strong magnetic field, and low resistance to magnetization changes and use it to build the electric machine cores, enabling a new class of power-dense and high-performance electric machines. Second, the machine stator material will be coated with ceramic electrophoretic deposition insulation, with 10X higher thermal conductivity than state of the art. With these new materials and manufacturing methods, the team aims to significantly improve torque density by 40% to 70%, and reduce the manufacturing costs of electric machines for EVs.
If successful, this project’s outcomes can revolutionize the design concept and manufacturing of the electric machine industry.