M. Hays
Orbis Electric,
United States
Keywords: anisotropic field orientation, enhance flux density permanent magnet electric machines
Summary:
A novel approach to rotor-integrated magnetic material architectures is presented that leverages anisotropic field orientation to enhance flux density and energy product in permanent magnet electric machines. The method utilizes spatially ordered arrays of non-rare-earth magnetic materials embedded directly within the rotor’s structural domain, enabling directional control over magnetization vectors and interfacial flux coupling. Through geometric anisotropy, compositional tailoring, and magnetic path optimization, the resulting array achieves localized flux amplification that compensates for lower remanence and coercivity inherent to ferrite and other alternative magnet chemistries. Finite element and analytical modeling demonstrate that anisotropic embedding reduces leakage flux, homogenizes torque production, and significantly increases effective magnetic utilization per unit mass. Experimental data further validate the potential of these architectures to achieve neodymium-equivalent torque densities with reduced reliance on critical rare-earth materials. The framework establishes a scalable path toward sustainable magnet-motor integration through engineered anisotropy and field-aligned rotor material architectures