Structures Utilizing a Structured Magnetic Material and Methods for Making

Patent metadata

Field	Value
Publication number	US-2016043602-A1
Application number	US-201414501668-A
Country	US
Kind code	A1
Filing date	Sep 30, 2014
Priority date	Sep 30, 2013
Publication date	Feb 11, 2016
Grant date	—

Abstract

A motor comprises a stator comprising at least one core; a coil wound on the at least one core of the stator; a rotor having a rotor pole and being rotatably mounted relative to the stator; and at least one magnet disposed between the rotor and the stator. The at least one core comprises a composite material defined by iron-containing particles having an alumina layer disposed thereon.

First claim

What is claimed is:

1 . A motor, comprising:
a stator comprising at least one core; a coil wound on the at least one core of the stator; a rotor having a rotor pole and being rotatably mounted relative to the stator; and at least one magnet disposed between the rotor and the stator; wherein the at least one core comprises a composite material defined by iron-containing particles having an alumina layer disposed thereon.

2 . The motor of claim 1 , wherein the rotor pole and the stator in conjunction with the at least one magnet directs magnetic flux between the rotor and the stator in directions that are outside of a single plane in three dimensions.

3 . The motor of claim 1 , wherein the stator is configured to approximate a cross sectional shape that defines surfaces corresponding to a cross sectional shape of the at least one magnet.

4 . The motor of claim 1 , further comprising a conical air gap between the stator and the at least one magnet.

5 . The motor of claim 4 , wherein the rotor pole is extended in the direction of the stator to produce the conical air gap between the stator and the at least one magnet.

6 . The motor of claim 1 , wherein the coil is tapered in the radial direction.

7 . The motor of claim 1 , wherein the at least one core is formed on a surface of the stator to form a slotless stator.

8 . The motor of claim 1 , wherein the rotor comprises a first rotor portion and a second rotor portion.

9 . The motor of claim 1 , wherein the stator comprises at least a first stator portion and a second stator portion.

10 . A motor, comprising:
a slotless stator comprising at least one core formed of a soft magnetic composite material and coils disposed on the at least one core; a rotor rotatably mounted relative to the slotless stator; and at least one magnet mounted on the rotor between the rotor and the slotless stator; wherein the soft magnetic composite material comprises particles containing at least iron and having insulating outer surfaces comprising alumina.

11 . The motor of claim 10 , wherein the particles containing at least iron comprise an iron-aluminum alloy.

12 . The motor of claim 11 , further comprising an air gap between the slotless stator and the at least one magnet, the air gap being conical in cross sectional shape.

13 . The motor of claim 10 , wherein the slotless stator comprises a wall that forms a continuous surface on which the at least one core is formed.

14 . The motor of claim 10 , wherein the soft magnetic material comprises about 89 wt. % iron, about 10 wt. % aluminum, and about 0.25 wt. % carbon.

15 . The motor of claim 14 , wherein the soft magnetic material further comprises silicon.

16 . A slotless flux motor, comprising:
a stator defined by a continuous surface at which at least one core is disposed and a winding disposed on the at least one core; a rotor having a rotor pole and being rotatably mounted in the stator; and at least one magnet mounted between the stator and the rotor pole; wherein a conical air gap is defined between the stator pole and the at least one magnet, wherein the conical air gap allows flux flow along radial, axial, and circumferential directions of the motor; and wherein the at least one core comprises a soft magnetic composite material defined by iron-containing particles encapsulated in alumina.

17 . The slotless flux motor of claim 16 , wherein the iron-containing particles comprise an iron-aluminum alloy comprising about 89 wt. % iron, about 10 wt. % aluminum, and about 0.25 wt. % carbon.

18 . The slotless flux motor of claim 17 , wherein the iron-containing particles further comprise silicon.

19 . The slotless flux motor of claim 16 , wherein the iron-containing particles include one or more of iron-cobalt alloy, iron-nickel alloy, and iron-silicon alloy.

20 . The slotless flux motor of claim 16 , wherein the at least one core is self-supported on an inner-facing surface of the stator and has a horizontal V-shaped cross section.

Assignees

• Persimmon Technologies Corp

Inventors

• Hosek Martin
• Sah Sripati
• Krishnasamy Jayaraman

Classifications

• H02K21/12

  with stationary armatures and rotating magnets · CPC title

• H02K1/02

  characterised by the magnetic material · CPC title

• C22C2202/02

  Magnetic · CPC title

• H02K1/22

  Rotating parts of the magnetic circuit · CPC title

• H02K1/12

  Stationary parts of the magnetic circuit · CPC title