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The original brush and brushless DC motor structures presented in this paper make use of a special winding technique which presents several advantages: the copper volume of the motor is minimized, the mechanical structure is well adapted to the pressing process because the armature is designed with a small number of relatively wide slots and the winding process is easier. The isotropic properties of soft magnetic composites are also used to design a magnetic circuit where the magnetic flux is circulating in three dimensions. It is then possible to maximize the torque-to-weight ratio and to minimize the total axial length of the motor. This paper describes an efficient use of a new technology of magnetic material that needs a new structural design approach taking into account the advantages and constraints of the material, and that the direct replacement approach is usually not optimal.

Iron-resin composites or dielectromagnetic materials are designed for AC and pulsed DC electromagnetic applications. These new materials present interesting features such as ease of shaping, high induction, low losses and isotropic electrical, thermal and magnetic properties. Compared to steel laminations, better performing and/or more compact devices may result from an optimisation of the design taking full advantage of these isotropic properties. Also, compared to soft ferrites, dielectromagnetics show higher magnetic saturation and much better machinability. In this paper, potential applications for this type of material in the automotive industry together with their specific requirements are discussed. The characteristics of a new dielectromagnetic material, ATOMET EM-1, are described.