Structures utilizing a structured magnetic material and methods for making

Patent metadata

Field	Value
Publication number	US-9887598-B2
Application number	US-201414501668-A
Country	US
Kind code	B2
Filing date	Sep 30, 2014
Priority date	Sep 30, 2013
Publication date	Feb 6, 2018
Grant date	Feb 6, 2018

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 and an outer wall, the outer wall extending in an axial direction;
a coil wound on the at least one core of the stator such that an edge of the outer wall extending in the axial direction is below, even with, pr extends beyond a surface of the coil facing in the axial direction and such that the outer wall terminates at an outer edge of the coil;
a rotor having a rotor pole and being rotatably mounted relative to the stator;
at least one magnet disposed between the rotor and the stator; and
a conical air gap between the stator and the at least one magnet;
wherein a separation plane normal to an axis of rotation extends through the stator and the rotor, and wherein the coil, the at least one magnet, and the conical 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 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 2 , wherein the outer wall inhibits the direction of magnetic flux radially outward from the stator beyond the outer wall.

4. 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.

5. The motor of claim 1 , 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. The motor of claim 1 , wherein substantially all of the magnetic flux is directed circumferentially along the edge of the outer wall to adjacent coils.

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

12. The 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.

13. The motor of claim 1 , wherein the at least one core comprises a composite material defined by iron-containing particles having an alumina layer disposed thereon.

14. A motor, comprising:
a slotless stator comprising at least one core formed of a soft magnetic composite material, an outer wall positioned along a circumference of the at least one core, and coils disposed on the at least one core, the outer wall positioned along the circumference of the at least one core extending in an axial direction such that an edge of the outer wall is below, even with, or extends beyond a surface of the coil facing in the axial direction and such that the outer wall terminates at an outer edge of the coils disposed on the at least one core;
a rotor rotatably mounted relative to the slotless stator;
at least one magnet mounted on the rotor between the rotor and the slotless stator; and
an air gap between the slotless stator and the at least one magnet, the air gap being conical in cross sectional shape;
wherein a separation plane normal to an axis of rotation extends through the slotless stator and the rotor, and wherein the coils, the at least one magnet, and the conical air gap are together configured to allow flux flow between the slotless stator and the rotor in a three-dimensional flux pattern such that the flux flow does not cross the separation plane.

15. The motor of claim 14 , wherein the soft magnetic composite material comprises particles containing at least iron and having insulating outer surfaces comprising alumina.

16. The motor of claim 14 , wherein the slotless stator comprises a wall that forms a continuous surface on which the at least one core is formed.

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

18. The motor of claim 17 , wherein the soft magnetic material further comprises silicon.

19. 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 in an axial direction such that the edge of the outer wall is below, even with, or extends beyond a surface of the winding facing in the axial direction and such that the outer wall terminates at an outer edge of the 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;
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 conical 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; and
wherein the at least one core comprises a soft magnetic composite material defined by iron-containing particles encapsulated in alumina.

20. The slotless flux motor of claim 19 , 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.

21. The slotless flux motor of claim 20 , wherein the iron-containing particles further comprise silicon.

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

23. The slotless flux motor of claim 19 , 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
• Persimmon Tech Corporation

Inventors

• Hosek Martin
• Sah Sripati
• Krishnasamy Jayaraman

Classifications

• H02K1/02

  characterised by the magnetic material · CPC title

• C23C8/02

  Pretreatment of the material to be coated (C23C8/04 takes precedence) · CPC title

• C23C4/06

  Metallic material · CPC title

• C22C2202/02

  Magnetic · CPC title

• H02K21/12

  with stationary armatures and rotating magnets · CPC title