Structures Utilizing a Structured Magnetic Material and Methods for Making

Patent metadata

Field	Value
Publication number	US-2020153303-A1
Application number	US-202016741111-A
Country	US
Kind code	A1
Filing date	Jan 13, 2020
Priority date	Sep 30, 2013
Publication date	May 14, 2020
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 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, an outer wall circumferentially positioned around the at least one core, an edge of the outer wall extending radially beyond an outer edge of the winding disposed on the at least one core and between an upper edge of winding and a lower edge of the winding; 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 V-shaped air gap is defined between the stator pole and the at least one magnet, wherein the V-shaped air gap includes a spacer and allows flux flow along radial, axial, and circumferential directions of the motor; and wherein a separation plane normal to an axis of rotation extends through the stator and the rotor, and wherein the at least one magnet and the V-shaped air gap are together configured to allow flux flow between the stator and the rotor in a three-dimensional flux pattern such that the flux flow does not cross the separation plane.

2 . The slotless flux motor of claim 1 , 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.

3 . The slotless flux motor of claim 1 , wherein an outer-facing surface at a back wall of the stator has a cutout.

4 . The slotless flux motor of claim 1 , wherein a cutout at an outer-facing surface at a back wall of the stator has a uniform cross sectional shape to provide uniform flux distribution in one or more portions of the stator.

5 . The slotless flux motor of claim 1 , wherein the at least one core comprises a soft magnetic composite material defined by iron-containing particles encapsulated in alumina.

6 . The slotless flux 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.

7 . The slotless flux 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.

8 . The slotless flux motor of claim 1 , wherein the rotor pole is extended in the direction of the stator to produce the V-shaped air gap between the stator and the at least one magnet.

9 . The slotless flux motor of claim 1 , wherein the at least one magnet comprises two magnets, each of the two magnets being magnetized in different directions.

10 . The slotless flux motor of claim 1 , wherein the rotor comprises a first rotor half and a second rotor half, and wherein the motor is configured to operate based on rotation of either the first rotor half or the second rotor half.

11 . A slotless flux motor, comprising:
a stator defined by a continuous wall having an upper edge and a lower edge and a soft magnetic core defined directly on an inner-facing surface of the continuous wall between the upper edge and the lower edge so as to be flush with the upper edge and the lower edge of the continuous wall, and a potted winding disposed on an inner-facing surface of the soft magnetic core, the outer-facing surface terminating beyond an outermost edge of the winding; 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 V-shaped air gap is defined between the stator and the at least one magnet, wherein the V-shaped air gap includes a spacer and allows flux flow along radial, axial, and circumferential directions of the motor; and wherein a separation plane normal to an axis of rotation extends through the stator and the rotor, and wherein the at least one magnet and the V-shaped air gap are together configured to allow flux flow between the stator and the rotor in a three-dimensional flux pattern such that the flux flow does not cross the separation plane.

12 . The slotless flux motor of claim 11 , wherein the soft magnetic core has a V-shaped cross section.

13 . The slotless flux motor of claim 11 , wherein the rotor comprises a first rotor half and a second rotor half, and wherein the motor is configured to operate based on rotation of either the first rotor half or the second rotor half.

14 . The slotless flux motor of claim 11 , wherein the soft magnetic core comprises a soft magnetic composite material defined by iron-containing particles encapsulated in alumina.

15 . The slotless flux motor of claim 11 , 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.

16 . The slotless flux motor of claim 11 , 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.

17 . The slotless flux motor of claim 11 , wherein the rotor pole is extended in the direction of the stator to produce the V-shaped air gap between the stator and the at least one magnet.

18 . The slotless flux motor of claim 11 , wherein the at least one magnet comprises two magnets, each of the two magnets being magnetized in different directions.

Assignees

• Persimmon Technologies Corp

Inventors

• Hosek Martin
• Sah Sripati
• Krishnasamy Jayaraman

Classifications

• B22F3/115

  by spraying molten metal, i.e. spray sintering, spray casting · CPC title

• C23C8/10

  Oxidising · CPC title

• H01F41/0246

  Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36) · CPC title

• C23C4/06

  Metallic material · CPC title

• H02K1/22

  Rotating parts of the magnetic circuit · CPC title