Ford is revolutionizing electric motor technology with a new patent filed at the European Patent Office, utilizing soft magnetic composites (SMCs) to enhance manufacturing speed, efficiency, and power output.
As the mass adoption of electric vehicles accelerates, every new EV introduces advancements in battery range and motor performance. Ford’s innovative use of SMCs represents a significant leap forward, promising lighter, more efficient motors that are quicker and cheaper to produce—paving the way for the next generation of EV propulsion systems.
What Are SMCs?
Soft magnetic composite materials are fairly typical in electromagnetic applications and comprise ferromagnetic powder particles that are surrounded by an insulating film. They are made using various compaction and annealing techniques. Compared to laminated steel cores, they offer several advantages in electromagnetic applications, including:
- Fairly low total core losses at medium to high frequencies
- Low eddy current losses
- Better thermal characteristics
- Allow more flexible motor design
- Much lower weight
- Lower production cost
- Better magnetic properties
- Act as electrical insulation
Ford Wants To Incorporate SMCs In EV Motors
Thanks to their proven advantages, it’s only a matter of time before SMCs become commonplace in electric motors used in EVs, and Ford wants to be at the forefront with its new patent application. It proposes a new kind of stator and rotor for use in electric motors that uses SMCs as inserts to replace traditional inserts, with its insulating properties enabling manufacturers to completely replace traditional paper insulation.
Our Take
Ford says the new design will result in electric motors with more torque and improved efficiency. The motors will be cheaper and quicker to manufacture to boot. The advantages make them ideal for electric vehicles, where range anxiety is still a problem while the industry tries to balance charging infrastructure with the number of EVs on the roads. As efficiency and battery driving range are both improved with SMC motors, everybody stands to gain from this patent, while the lower production costs will help drive down EV prices to accelerate mass adoption.
