METHOD FOR MANUFACTURING AN ELECTRICAL MACHINE
First Claim
1. A method for manufacturing an electrical machine, comprising:
- (a) stacking a plurality of rotor laminations to form an axial rotor segment, the rotor segment formed of at least two laminations, each rotor lamination having a plurality of curvilinear slots therein, the curvilinear slots forming a plurality of rotor poles in the rotor segment, each pole having a plurality of curvilinear passages formed from the curvilinear slots;
(b) rotating the rotor segment to place a first pole of the plurality of poles in an alignment position;
(c) injecting into the curvilinear passages of the first pole a polymer bonded permanent magnet material in molten form, wherein the polymer bonded permanent magnet material includes magnetic particles suspended within a polymeric matrix;
(d) subjecting the first pole to a desired magnetic field to align the magnetic particles into a desired orientation prior to solidification of the polymer bonded permanent magnet material;
(e) solidifying the polymer bonded permanent magnet material to form permanent magnets within the curvilinear passages of the first pole; and
(f) after performing (e) for the first pole, performing (b), (c), (d), (e) for each remaining pole of the plurality of poles.
1 Assignment
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Accused Products
Abstract
A method for manufacturing for an electrical machine includes: stacking a plurality of rotor laminations to form an axial rotor segment, the rotor segment formed of at least two laminations, each lamination having a plurality of openings therein, the openings forming a plurality of rotor poles in the rotor segment, each pole having a plurality of passages formed from the openings; rotating the rotor segment to place a first pole of the plurality of poles in an alignment position; injecting into the passages of the first pole a polymer bonded permanent magnet (PBM) material in molten form, wherein the (PBM) material includes magnetic particles suspended within a polymeric matrix; subjecting the first pole to a desired magnetic field to align the magnetic particles into a desired orientation prior to solidification of the (PBM) material; and solidifying the (PBM) material to form permanent magnets within the passages of the first pole.
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Citations
21 Claims
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1. A method for manufacturing an electrical machine, comprising:
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(a) stacking a plurality of rotor laminations to form an axial rotor segment, the rotor segment formed of at least two laminations, each rotor lamination having a plurality of curvilinear slots therein, the curvilinear slots forming a plurality of rotor poles in the rotor segment, each pole having a plurality of curvilinear passages formed from the curvilinear slots; (b) rotating the rotor segment to place a first pole of the plurality of poles in an alignment position; (c) injecting into the curvilinear passages of the first pole a polymer bonded permanent magnet material in molten form, wherein the polymer bonded permanent magnet material includes magnetic particles suspended within a polymeric matrix; (d) subjecting the first pole to a desired magnetic field to align the magnetic particles into a desired orientation prior to solidification of the polymer bonded permanent magnet material; (e) solidifying the polymer bonded permanent magnet material to form permanent magnets within the curvilinear passages of the first pole; and (f) after performing (e) for the first pole, performing (b), (c), (d), (e) for each remaining pole of the plurality of poles. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for manufacturing a rotor for an electrical machine, comprising:
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stacking a number of rotor laminations on a mandrel to achieve a rotor segment extending in an axial direction parallel to the mandrel, wherein the mandrel is constructed to align the rotor laminations in a desired rotational orientation relative to each other, wherein the laminations have a plurality of openings therein, wherein the stacked rotor laminations form a rotor segment;
wherein the plurality of openings form a plurality of passages extending through the rotor segment; and
wherein the rotor segment has a plurality of poles;selecting a pole for forming therein a permanent magnet; injecting the pole with a polymer bonded permanent magnet material in molten form, wherein the polymer bonded permanent magnet material includes magnetic particles suspended within a polymeric matrix; aligning the magnetic particles within the polymer matrix into a desired orientation using a desired magnetic field; solidifying the polymer bonded permanent magnet material to form a solid permanent magnet; and after the solidifying, repeating the selecting, injecting, aligning and solidifying for each pole of the plurality of poles. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20)
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21. A method for manufacturing an electrical machine, comprising:
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(a) stacking a plurality of rotor laminations to form an axial rotor segment, the rotor segment formed of at least two laminations, each rotor lamination having a plurality of curvilinear slots therein, the curvilinear slots forming a plurality of rotor poles in the rotor segment, each pole having a plurality of curvilinear passages formed from the curvilinear slots; (b) rotating the rotor segment to place a first pole of the plurality of poles in an alignment position; (c) filling the curvilinear passages of the first pole with a polymer bonded permanent magnet material, wherein the polymer bonded permanent magnet material includes magnetic particles suspended within a polymeric matrix; (d) subjecting the first pole to a desired magnetic field to align the magnetic particles into a desired orientation prior to solidification of the polymer bonded permanent magnet material; (e) solidifying the polymer bonded permanent magnet material to form permanent magnets within the curvilinear passages of the first pole; and (f) after performing (e) for the first pole, performing (b), (c), (d), (e) for each remaining pole of the plurality of poles.
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Specification